Search - November 2012 by Infomedia18

EXCELLENCE BY INCLUSION, NOT BY SELECTION igh-profile panelists, tall claims, mock topics, high-end venue, best of stage design, dietdefying food, small talks, short changed audience…this sums-up the mushrooming of the so called ‘knowledge forums’ which one tends to attend lately. With this as a reality canvas and with the ‘me too’ DNA completely missing in the way we are created, the need to initiate a panel discussion ourselves was never felt by the ‘magazine’ people (that happens to be us). Then a simple question by a genuine reader stumped the ‘front foot’ playing team (that is Network18 Publishing). This gentleman happens to be an avid reader of SEARCH for the past many years, and it also happens that last year, he participated in our own homegrown show Engineering Expo, which is an established trade exposition and an enabling extension of SEARCH, displaying the same sense of responsibility towards the core value that needs to be created for the value chain. Now, this reader of SEARCH did not know that Engineering Expo is a presentation of SEARCH. When he figured out this fact, he had one simple question for us: Isn’t there a gap between the two streams of value creations? Is there a need to build a bridge between the magazine and the trade show? Is there a need to build a Knowledge Nexus? Like it is true with a lot of things, we were also working in our silos…islands of excellence, but with little synergic co-existence…if you ask why this piece of information is relevant, my answer is very simple…just like our organisation, which happens to be the complete media solutions company, internally, we took some time to synergise and maximise our offerings. Well, here we are! Fresh with an afterglow of a very successful and humbling experience as SEARCH responded to the need of the industry, which saw a high-voltage panel discussion that coincided as a prelude to the 11th edition of Engineering Expo Ahmedabad. Themed ‘The Shifting Status: From Share Taker to Marker Maker’, it was a right forum and the right representation of both panelists and attendees, who believed in doing justice to the task in hand. To top that, the inspiration himself had sent out a very special message and Mr Narendra Modi’s gesture of writing a special note was very well received. Mr Maheshwar Sahu, Principal Secretary – industries & Mines, Government of Gujarat; Dr Bakul Dholakia, Director, Adani Institute of Infrastructure Management & Advisor to Adani Group; Mr Sunil Shah, Chairman, Gujarat Innovation Society and Mr Mahendra Singh Dhakad, Programme Director, UNIDOICAMT, were among the group of elite panelists who voiced their views. Never believing in limiting our efforts towards making the industrial growth of India more robust, SEARCH is all set to host seven more panel discussion, one every month. Pune, Chennai, Ludhiana, Indore, Aurangabad, Rudrapur & Hyderabad, these ‘Knowledge Nexus’ will prompt us to work with you closely, to understand and eliminate the unique hurdles of growth in each region. We will be keen to hear from you on ways to maximise these meetings, as we can never over-emphasise how these networks, each in their own way, are indispensable to the further advancement of the industry’s level of excellence. The belief that excellence should be derived by inclusion not by selection is the guiding philosophy when we reach your cities/regions and be the change that you want to see! In this crowd of ‘forums’ that strive for excellence by selection, we believe that India’s inclusive growth can only be attained by including everybody and that’s what we call creating excellence by inclusion!

Archana Tiwari-Nayudu archana.nayudu@network18publishing.com

CONTENTS SPECIAL FOCUS: Paints, Coatings & Polishes

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Paints’ Selection Criteria Decoding Material Formulation Material composition of paints is decided in accordance with the application, cure rate, cost, mechanical properties, durability, anti-oxidation properties and colour requirements. Further, the mixing depends on the polishing agenda, solvents, emulsifiers and auxiliary materials, such as preservatives, colourants and fragrance. Here’s taking a look at how the formulation of materials is coded...

EDITORIAL

POLICIES & REGULATIONS

Excellence By Inclusion, Not By Selection

130

NEWS, VIEWS & ANALYSIS 36

Latest Happenings In The World Of Manufacturing

STRATEGY 132

Leadership Mantra Followers Make Leaders

134

Opinions & More ‘FDI In Mining Is Increasing The Growth Of Domestic End-user Segments In India’ Venkatesan Subramanian, Director – Metals & Minerals

NEWS ANALYSIS 44

Export Package Developing Industry Through Exports

Power Problems A Roadblock In India’s Growth Story

Practice, South Asia, Middle East and North Africa, Frost & Sullivan

TECHNOLOGY & INNOVATIONS 49

Technology Acquisition And Development Fund Laying A Strong Foundation For NIMZs

Technology Update Cutting-edge Solutions

TIPS & TRICKS 136

Paints & Polishes Selection Guide 7 Steps To Enhance Durability

IN CONVERSATION WITH

CASE STUDY 112

Siemens’ NX™ Digital Product Development System Delivering The World’s Most Powerful Diesel Engine

Pg 52

AUTOMATION TRENDS 114

Robotics Enhancing Lean Manufacturing Environments

ENERGY MANAGEMENT 122

Automation Solutions Key To Harnessing Vast Renewable Resources

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Opinions & More ‘Today, Saving Energy Is At The Forefront Of Our Purchasing Decisions’ Dr S Pekka Hakkarainen, VP, Lutron Electronics Co Inc

HIGHLIGHTS: DECEMBER 2012 ●

Year-ender: Best Of 2012 ●

Special Edition: Made In Germany

‘Think global is going to be a survival strategy’ JG Kulkarni, EVP, CG, who has been recently appointed as President, Indian Electrical & Electronics Manufacturers’ Association (IEEMA)

CONTENTS SPECIALS IN THIS ISSUE SPECIAL FOCUS Paints, Coatings & Polishes

Open Page

Corrosion-resistant Coatings ‘Coat’ To Keep Corrosion Away

New Age Paints And Polishes Offering Manufacturers A Hue Of Productivity

INSIGHTS & OUTLOOK Oil, Coolants & Lubricants

Industrial Applications Integrating Aesthetics With Durability Industrial Paints & Polishes Designing The World Beyond Imagination

ERP For Paints Industry Stock It Right!

Open Page

Oil Selection Parameters How Healthy Is Your Oil?

Antifreeze Coolants Corrosion Inhibitors @ Work

3D Modeling And Rapid Prototyping Of A Cryogenic Liquefier Coolant Enhancement Via Liquefaction

104

New Age Maintenance Technologies How Painful Is Flushing The Coolant Out?

106

Vacuum Distillation Technology Recycling Gets Tech Advantage

Diesel Fuel Lubricity Boon Or Bane?

Refining Oil Depreciating The Lubricating Value?

Motor Oil Selection Guide How Well Do You Know Your Motor Oil?

PRODUCT UPDATE

CURTAIN RAISER

140

New Launches Latest Products In The Offing

193

Engineering Expo Pune 2012 Facilitating Business On A Higher Plane

146

Paints, Coatings & Polishes Latest Products In Paints, Coatings & Polishes

195

Engineering Expo Chennai 2012 Offering A Competitive Advantage

148

Oil, Coolants & Lubricants Latest Products In Oil, Coolants & Lubricants

197

TENDERS

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General Products Rolling Out The Best In Class

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PRODUCT INDEX

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EVENTS’ LIST EVENT REPORT

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Engineering Expo Ahmedabad 2012 Epitomising Entrepreneurial Excellence

192

Panel Discussion: Gujarat Flying High With Successful Strategies

Alphabetical Listing Of Products Presented In The Issue

208

ADVERTISERS’ LIST Advertisers’ List In Chronological Order Cover Illustration: Sachin Pandit

Looking For A Speciﬁc Product?

PRODUCT UPDATE

Searching and sourcing products were never so easy. Se JJust type SRCH (space) Product Name and send it to 51818

eg. SRCH Pump and send it to 51818 eg

FOUNDER & EDITOR, NETWORK 18 Raghav Bahl PRESIDENT & EDITORIAL DIRECTOR, TV 18 Senthil Chengalvarayan EXECUTIVE EDITOR Archana Tiwari-Nayudu EDITORIAL TEAM Kimberley D’Mello, Nishi Rath, Prateek Sur, Archana Singh, Arindam Ghosh (Delhi), Suprita Anupam (Bengaluru) ASSISTANT ART DIRECTOR Varuna Naik DESIGN TEAM Sanjay Dalvi CHIEF PHOTOGRAPHER Mexy Xavier PHOTOGRAPHY Neha Mithbawkar, Joshua Navalkar BUSINESS CONTROLLERS Lovey Fernandes, Akshata Rane, Shefali Mahant, Israr Shaikh Deepak Bhatia, Ashish Kukreti, Shwetha ME, Jayashree N

PRINTING EXECUTIVE VICE PRESIDENT Ananth R Iyer ASSISTANT GENERAL MANAGER - PPC Shekhar Khot

PRODUCTION TEAM Surekha Karmarkar, Ravikumar Potdar Ravi Salian, Sanjay Shelar

OVERSEAS CONTACT Ringier Trade Media Ltd

CHINA 1001 Tower 3, Donghai Plaza, 1486 Nanjing Road, West, Shanghai 200040, China Tel: +86-21 6289 – 5533 Ext. 368, Fax: +86-21 6247 – 4855 (Craig Shibinsky) Email: craig@ringier.com.hk Ringier Trade Media Ltd

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GROUP CEO, NETWORK 18 B Sai Kumar CEO-NETWORK 18 PUBLISHING Sandeep Khosla EVP-HUMAN RESOURCES Sanjeev Kumar Singh ASSOCIATE VICE PRESIDENT Sudhanva Jategaonkar ADVERTISING SALES Shashin Bhagat (Ahmedabad) shashin.bhagat@network18publishing.com Mahadev B (Bengaluru) mahadev.b@network18publishing.com Hari Hara Subramaniam (Chennai) hari.s@network18publishing.com Balakrishnan S (Coimbatore) Balakrishnan.s@network18publishing.com Mukesh Yadav (Delhi) mukesh.yadav@network18publishing.com Dominic Dsouza (Hyderabad) dominic.dsouza@network18publishing.com Ameya Gokhale (Indore) ameya.gokhale@network18publishing.com Sandeep Arora (Jaipur) sandeep.arora@network18publishing.com Abhik Ghosal (Kolkata) abhik.ghosal@network18publishing.com Inder Dhingra (Ludhiana) inder.dhingra@network18publishing.com Olwin Desouza (Mumbai) olwin.desouza@network18publishing.com Rohit Dass (Pune) rohit.dass@network18publishing.com Vipul Modha (Rajkot) vipul.modha@network18publishing.com Chirag Pathak (Vadodara) chirag.pathak@network18publishing.com MARKETING TEAM Ganesh Mahale, Prachi Mutha, Akshaya Jadhav

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Views and opinions expressed in this magazine are not necessarily those of Network18 Media & Investments Ltd (Network18)*, its publisher and/or editors. We at Network18 do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Network18 does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Network18 does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Network18 reserves the right to use the information published herein in any manner whatsoever. Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18. Executive Editor: Archana Tiwari-Nayudu Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028.

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* ownership of this magazine stand transferred from Infomedia18 Limited (Infomedia18) to Network18 Media & Investments Limited (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia18 and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.

NEWS, VIEWS & ANALYSIS L A T E S T

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PANASONIC TO MAKE INDIA MANUFACTURING HUB Panasonic will commence exporting home appliances from India as part of its strategic plans to make the country a manufacturing hub. The first shipment is likely to happen by 2014–15. With the commissioning of the $200-million facility at Jhajjar, Haryana, by December 2012, the company’s production in India will get a boost. Once the company operationalises and commissions the upcoming Jhajjar plant, it will consider expanding the reach of its products to other countries as well. The company has not finalised products that will be exported, but it is likely to start with air conditioners and washing machines. After the Jhajjar plant gets operationalised by December 2012, it will start with production of airconditioners and washing machines. Within a year, the company plans to

roll out refrigerators and microwaves from there. The production capacity of air conditioners will be 10 lakh units annually, while for washing machines, it will be three lakh units. Panasonic India currently manufactures LCD panels at its Noida facility and automatic rice cookers at its Chennai plant. The Noida plant has a capacity of six lakh units per annum, whihc will be expanded to 10 lakh units next year. The Japanese giant said, it is targeting an over two-fold jump in revenue to `12,500 crore from its consumer durables business in India by 2015 as part of an overall plan to become a `25,000-crore business entity in the country. In the last fiscal, the consumer durables division had a revenue of `3,200crore. This fiscal, it is targeting `5,500crore.

BLACKSTONE INVESTS $100 MILLION IN INTERNATIONAL TRACTORS LTD The Blackstone Group recently announced that its affiliate, Blackstone Capital Partners (Singapore), has signed an agreement to acquire 12.5% of International Tractors Ltd (ITL) in a structured transaction for up to $100 million. The flagship company of Sonalika Group, ITL is a leading manufacturer of tractors under the brand name ‘Sonalika’. Incorporated in 1995, ITL has grown to have an annual turnover of $500 million. ITL exports tractors to over 70 countries across the globe. As the favourable macro-economic trends like rising minimum support prices and rising labour costs are leading to increased adoption of mechanisation by farmers, ITL’s cost-effective manufacturing facilities with deep value engineering and strong product development capabilities provide it with a competitive advantage to capture this market.

SUZLON BAGS 8.4 MW PROJECT IN GUJARAT Wind turbine maker Suzlon has recently bagged a contract from Surat Municipal Corporation (SMC) to set up a 8.4-MW project in Gujarat. The company will have to set up, operate and maintain 8.4 MW project, which comprises of four units of Suzlon’s S95-2.1 MW turbines, according to the company statement. The new project will augment SMC’s existing wind power portfolio to 11.4 MW. Once commissioned,

the project will help SMC reduce its carbon footprint by eliminating around 15,000 tonne of CO2 emissions per annum, the release said. The company had supplied a maiden 3 MW wind power project in 2010 for the SMC in Adodar, Gujarat. The fifth-largest turbine maker, with an installed capacity of over 1.5 GW, has also built the largest wind farm in the country in Kutch.

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GAMESA TO SUPPLY TOSHIBA WITH 30 MW OF WIND TURBINES FOR ITALY Gamesa Corporacion Tecnologica SA (GAM), Spain’s biggest windturbine maker, will supply Toshiba Corp. (6502) with 30 megawatts of the machines for an Italian power project. Gamesa will supply 15 turbines of 2 megawatts each to the site in Brindisi, Puglia, with installation starting before the year-end, Zamudio-based Gamesa recently said in a statement. The order was signed with Genova-based Toshiba Europe T&D, the contractor on the project developed by Eolica Erchie. Terms were not disclosed. Gamesa has installed 1,506 megawatts of turbines in Italy since entering the market in 2002, it said.

VARROC PURSUES AUTO SECTOR, SELLS JV STAKE TO PLASTIC OMNIUM Indian auto parts supplier Varroc Group and France’s Plastic Omnium have ended their joint venture in India. Aurangabad-based Varroc sold its 46% stake in the auto exterior venture to Plastic Omnium. The JV, Plastic Omnium Varroc, has operated in Chakan, India, since 2007. Varroc is looking at expanding its polymer division by setting up three new facilities in different parts of India to cater to the various automobile hubs. The company is investing around $20m in the plants. The first, in Pithampur, will start production in October. The plant—Varroc’s eighth plastics operation—will supply Mahindra & Mahindra and VE Commercial Vehicles. The plant, on a 12.5-acre site, has injection presses ranging from 450– 850 tonne of clamping force. The second plant, in Bengaluru, will open next year. The third plant, in Chennai, will open in 2014.

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OIL, IOC ACQUIRE 30% STAKE IN US FIRM CARRIZO FOR $82.5 MN State-owned Oil India Ltd (OIL) and Indian Oil Corp (IOC) jointly bought 30% stake in Houston-based Carrizo Oil & Gas’s Niobrara shale oil and gas assets in Colorado for $82.5 million. In their first shale asset overseas, the OIL-IOC combine will make an upfront payment of $41.25 million to Carrizo and pay a similar amount for future drilling costs on behalf of the US firm. OIL will acquire 20% and IOC will get 10% in the Denver-Julesburg basin in Colorado, which produces both natural gas and liquids. Carrizo, which holds 61,500 gross acre in the Niobrara basin, currently produces 1,850 barrels of oil-equivalent per day, of which 30% would now accrue to OIL-IOC combine. The joint venture would spend

$230 million over the next 3–4 years on the shale property. OIL-IOC paid about $3,000 per acre for the 18,450-acre spread over three counties in Texas. Output from the field consists of about 69% of oil, 14% of natural gas liquids and 17% dry gas. OIL-IOC join Reliance Industries and GAIL India Ltd in the race for shale assets in the US to shore up energy security. RIL holds stake in three shale gas joint ventures in the US, including one with Carrizo in the Marcellus shale acreage in Pennsylvania. Gas utility GAIL India last year acquired a 20% stake in Carrizo’s Eagle Ford shale acreage. OIL plans to raise close to $100 million in foreign loans by year end to part-fund the Carrizo stake buy.

DAIMLER STARTS LIGHT TRUCK PRODUCTION IN INDIA Daimler India Commercial Vehicles, a unit of the world’s largest truck maker Daimler, has started production of its 9-tonne and 12-tonne light duty trucks at its plant in Oragadam near Chennai. Bharat Benz is the newest global truck maker to enter the Indian market, dominated by Tata Motors, which sells 60% of all trucks and Ashok Leyland sells around 20%. Last month, Daimler had launched three heavy-duty trucks, based on the Mercedes-Benz Axor platform, while the light trucks are based on Fuso Canter, Daimler’s brand based out of Japan. The Oragadam manufacturing plant has a capacity of 36,000 units for heavy and light trucks. Production of the heavy trucks had already started.The company has plans to launch 14 more models over the next 17 months in the 7–49 tonne range, it said after launching the heavy trucks. In the first phase, Bharat Benz trucks will be sold and serviced over a network of 17 dealerships, which will go up to 42 locations by the end of 2012 and by 2013, Bharat Benz dealers will be located across 108 locations, the company said.

MANUFACTURING SECTOR ACTIVITY REMAINS STEADY IN SEPTEMBER Faster output growth and an increase in export orders have helped India’s manufacturing sector to remain steady at 52.8 in September, according to the HSBC India Manufacturing Purchasing Managers’ Index (PMI) — a measure of factory production. The HSBC index has, however, remained above the 50-mark, below which it indicates contraction, for more than

three years now. Going forward, output growth is likely to weaken as post-production inventories of finished goods have increased significantly, the report said. The report also said that the inflation scenario was mixed, though output prices increased less, input prices rose at a faster pace due to higher raw material and diesel prices.

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

FINNISH POWER & ENERGY MAJOR FORTUM OPENS INDIA OFFICE IN NEW DELHI Finland-based energy company Fortum, a leading electricity and heat producer in northern Europe and Russia, has officially opened its Indian office in New Delhi. The main focus for the company will be to assess opportunities to invest in Combined Heat and Power (CHP) plants to provide power and steam for industrial clusters. Matti Kaarnakari has been appointed as the Managing Director of Fortum India Pvt Ltd. The company is looking to possibly make investments in the combined heat and power domain in India. It is currently in talks with stakeholders in several states. Meanwhile, Fortum also recently announced that it is exploring a possible future role in solar power production in India. Commenting on Fortum’s plans in India, Tapio Kuula, President & CEO, Fortum, said, “Our aim in India is to look into investment opportunities contributing to the development of India’s energy infrastructure. Based on our long track record in sustainable power and heat production and our energy market competence, I believe that Fortum has a lot to offer to the rapidly developing Indian energy market.” Commenting further on solar power production, he said, “India is one of the globally most interesting countries in solar power generation, both with regards to its natural location but also due to its ambitious plans for solar power. As we now have a base here in India, it is quite natural for us to explore possible growth in solar as well.”

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GE 9F 3-SERIES GAS TURBINES TO POWER NEW PROJECTS IN BANGLADESH GE has received contracts totaling $89 million to supply Frame 9F 3-series gas turbines, for two new power plants that will produce 675 megawatts of power to help expand Bangladesh’s power generation capacity. The projects will be the first in the country to feature GE’s advanced class gas turbine technology, delivering power with high efficiency, availability, reliability and low emissions. GE will provide one 9F 3-series gas turbine & parts to Isolux Ingenieria SA of Spain that is building the Siddirganj Power Plant for the Electricity Generation Company of Bangladesh Ltd. The second 9F 3-series gas turbine will go to Summit Corporation, an independent power producer that is building a new plant in Bibiyana, Bangladesh. GE, Isolux & Summit recently signed the contract at a ceremony in Dhaka, witnessed by GE Chairman Jeff Immelt, GE India CEO John Flannery along with Isolux Chairman Luis Delso, Summit Corporation Chairman Aziz Khan, the US Ambassador to Bangladesh and Bangladesh government officials. Jeff Immelt, Chairman, GE, said, “These two projects are an indication

of Bangladesh’s accelerated growth that is accentuated by rapid urbanisation; thereby increasing the demand for power. GE is committed to fostering innovations and technologies that build, power, move and help cure the world; this vision is an enabler that would help the people of Bangladesh live better lives.” “The Siddirganj project is an important step in the government’s initiative to increase Bangladesh’s supply of reliable and efficient power. We believe that GE’s advanced gas turbine technology, well proven in applications worldwide, is an excellent fit to ensure the success of this vital project,” said Luis Delso, Chairman, Isolux. “GE has an excellent track record of on-time delivery and strong technology support for projects around the globe. We are confident that they are the right supplier to help us successfully execute the Bibiyana II project,” said Aziz Khan, Chairman, Summit Corporation. The Siddirganj plant is expected to begin commercial operation in the fourth quarter of 2014, while the Bibiyana plant is expected to enter service in the second quarter of 2015.

ALSTOM EXPANDS THAI FOOTPRINT France’s Alstom is considering a plan to build a manufacturing facility for train components in Thailand. The facility in Thailand would serve not only the Thai market, but also exports. The French rail leader also dabbles in power generation & transmission and operates manufacturing facilities in Indonesia, China & India. Its train-related projects in Thailand include developing tracks for the Mass Rapid Transit Authority’s (MRTA) Blue Line and supplying diesel locomotives to the State Railway of Thailand. Apart from this, Alstom recently signed a five-year Memorandum of Understanding (MoU) with Kasetsart University’s (KU) engineering faculty to develop students in engineering fields for both the power and transport sectors. The goal is to produce 1,000 engineers during the five years. KU will introduce a Bachelor’s Degree programme in rail engineering, the first of its kind in Thailand, next semester. It hopes for 40 graduates a year. KU students will have the opportunity to enrich their technical knowledge and experience through on-the-job training at selected Alstom operations in Asia. With reported sales of 20 billion (794 billion baht) in the 2011–12 fiscal year, Alstom employs 92,000 people and operates in 100 countries.

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BHEL SETS UP FACILITY FOR ISRO BHEL has set up a facility at its Electronics Systems Division at Bengaluru in collaboration with Indian Space Research Organisation (ISRO) for assembling and testing Space Grade Solar Panels using high-efficiency solar cells. Besides, BHEL has also supplied two sets of Li-ion batteries—each consisting of 40 Li-ion cells with a power storage capacity of 160 Ampere-Hours—for GSAT-10, according to a statement released by BHEL. Both the solar panels and batteries were built and tested at the BHEL facility. They were subjected to rigorous tests such as vibration and thermal-vacuum tests at ISRO as part of ensuring space quality requirements to validate their mechanical, electrical and thermal performance. Earlier this year, space grade solar panels and Lithium-ion batteries assembled, tested and supplied by the electronics division of city-based BHEL to ISRO were successfully deployed recently on GSAT-10 Satellite. The satellite, launched from French Guiana on September 29, is the heaviest Indian satellite built by ISRO and caters to the country’s telecommunications and TV broadcasting requirements, a company release said. The four solar panels, of each with 5.36 sqmt area, supplied by BHEL for GSAT-10 comprise multi-junction solar cells in series and parallel combinations, with a total power generating capacity of 4,000 watts. BHEL has, so far, supplied 55 solar panels totalling to 250 sqmt of area and 40 batteries for various satellites of ISRO.

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SUCCESSFUL FLIGHT TESTING OF AGNI-IV DRDO-developed, 4,000-km range Nuclear Capable Ballistic Missile AGNI-IV, was successfully flight tested from Wheeler’s Island recently. This long range missile propelled by composite rocket motor technology, was tested for its full capability. The AGNI-IV missile launched from the road mobile launcher, reached the pre-defined target in about 20 minutes. The missile equipped with state-ofthe-art Avionics, 5th generation On Board Computer and with distributed architecture has the latest features to correct & guide for inflight disturbances. The most accurate Ring Laser Gyrobased Inertial Navigation System and supported by highly reliable redundant Micro Navigation System, ensured the vehicle reach the target

within two digit accuracy. The re-entry heat shield withstood temperatures of over 3,0000 centigrade and ensured the avionics function normally with inside temperature less than 500 centigrade. All Electro-Optical Tracking Systems, radars located all along the coast have tracked and monitored all the parameters throughout the flight. Two ships located near the target point tracked thevehicle and witnessed the final event. Dr Vijay Kumar Saraswat, SA to RM, Secretary Dept of Defence R&D and DG DRDO; Avinash Chander, Programme Director, AGNI, DS & CC R&D (MSS) reviewed the total launch activities and guided the team. Tessy Thomas, Project Director, AGNI-IV led the team of scientists during the operation.

IEEMA TO ORGANISE METERING INDIA 2013 The Meter Division of Indian Electrical and Electronics Manufacturers’ Association (IEEMA), has recently announced the 5th Seminar in the series of METERING INDIA, to be held on February 21 & 22, 2013 at New Delhi. The seminar would provide a forum for interaction on various issues related to energy metering in the country. This initiative by IEEMA is to provide deeper insights into the topics which are of utmost importance during the current scenario as well as the future into which Indian power sector is poised to take another quantum technological leap. According to Sunil Singhvi, Chairman – Meter Division, IEEMA, “With METERING INDIA 2013, we are at a very interesting milestone in our journey towards the smarter tomorrow. Utilities have invested heavily on the IT infrastructure, but are yet to use the data smartly. The last mile connectivity and

consumer participation has its own set of expectations from energy metering. Initiatives like Demand Side Management, Renewable Integration, Time of the Day (TOD) Tariff Implementation, Consumer Home Energy Management will add another dimension to revenue protection for the utility and the same may pose new challenges to the energy metering industry. Time has come to redefine the very purpose of metering beyond just metering in the context of smart future, hence the theme for the seminar has been selected as ‘A journey towards Smart Future’”. So far, METERING INDIA has received over 40 papers from various reputed organisations operating in electricity utilities, networking/ IT solutions providing companies, technical & research institutes and manufacturers of energy meters. The association expects over 100 papers for the event and more than 300 delegates attending the event.

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

SCHNEIDER ELECTRIC INDIA WINS ‘GOLD’ PRIZE AT THE FICCI SAFETY EXCELLENCE AWARDS FOR MANUFACTURING-2012 Schneider Electric India, the global specialist in energy management, has won the Gold Prize in the medium size category of FICCI Safety Excellence Awards for Manufacturing-2012 for its Hyderabad plant. The award was presented to Dr Satish Kumar, Energy Ambassador, Schneider Electric India and Bhavna Jaggi, Environmental, Health, and Safety Manager, Hyderabad plant, Schneider Electric India. Speaking on the occasion, Dr Kumar said, “We are honoured to be a part of the prestigious FICCI Safety Excellence Awards for manufacturing. Our Hyderabad plant follows class-leading systems and processes including safety measures & accurate control and remote monitoring of the plant.” Commenting on the achievement of the Hyderabad plant, Jaggi said, “The award comes as an acknowledgement of the safe and healthy work practices in our operations. Integration of behaviour based safety in day-to-day operations and, in particular, the detailed, systematic and scientific approaches to ergonomics at workplace are one of the key pillars of Schneider Production System (SPS).” Schneider Electric was selected from among over 37 companies that participated in the evaluation. The eminent Jury panel of FICCI Safety Excellence Awards for Manufacturing-2012 comprised of Dr R Chidambaram, Principal Scientific Advisor to Govt of India; Sompal, Former Minister of Agriculture & Member, Planning Commission; Surendra Singh, Former Cabinet Secretary; Rohit Relan, MD, Bharat Seats Ltd and Shyam Bang, Executive Director, Jubilant Life Sciences Ltd.

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DASSAULT SYSTÈMES SIMPLIFIES 3D DESIGN WITH SOLIDWORKS 2013 Dassault Systèmes, world leader in 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions, has introduced SolidWorks® 2013 with new and improved design applications to enhance collaboration, speed model creation and simplify the product development process. SolidWorks® 2013 combines ease of use with broad customisation, allowing new users to learn fast and experienced users to quickly become more productive at previously complex and sophisticated tasks. Building on the success of the last 20 releases, the new offering covers the range of SolidWorks applications for 3D design, simulation, technical communication, product data management, and sustainable design. Speaking on the occasion, Bertrand Sicot, CEO, SolidWorks, Dassault Systèmes, said, “With SolidWorks® 2013, we have upheld our tradition of listening to our customers by providing

enhancements and functionality to help them simplify their lives and create the best products. The new additions to core geometry and expanded product offerings demonstrate our continuing investment in our flagship product.” “SolidWorks® 2013 empowers innovative design with applicationspecific tools that help users quickly define, share & validate their designs’ the form, fit and function,” he added. Manoj Mehta, Country Manager – India & SAARC, Dassault Systèmes SolidWorks Corp, said, “The launch of SolidWorks® 2013 further reinstates our commitment to our customers for providing innovative products that enable manufacturers to enhance their productivity without compromising on quality. SolidWorks® 2013 incorporates several additions and enhancements that have been specifically recommended by our user community while maintaining the ease-of-use and interoperability of the product.”

SAIL INKS MoU WITH ABB FOR TECHNICAL TRAINING Steel Authority of India Ltd (SAIL) recently signed an MoU with ABB for technical training of its employees. The Swiss-based firm, ABB, will train over 4,000 SAIL employees in the next two years. This step is part of SAIL’s massive modernisation programme, wherein the company is trying to train their employees in new skills in modern technologies for better product quality and cost competitiveness. ABB will train the steel giant’s workforce at plant locations on specific equipment. ABB officials will begin the process by visiting five SAIL plants and drawing a yearly plan for on and off-plants training.

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

NISSAN PLANS SMALL CARS MADE IN INDIA Nissan is planning to develop a compact car fully made in India. The company’s Indian subsidiary, Nissan Motor India, is rapidly strengthening its Research and Development (R&D) wing for this purpose. International companies such as Toyota, Ford and market leader Maruti Suzuki have already done this with products developed majorly in India. Work on models including Etios, Etios Liva, Figo and Ertiga, respectively, were carried out in India keeping the Indian consumers in mind. Nissan Motor India has already recruited 3,000 people for the R&D centre. Nissan’s entry level car in India, at present, is the Micra premium hatchback priced at 4.21 lakh (ex-showroom Delhi). The company has six products on offer including three fully imported models. Nissan, earlier this year, announced the introduction of a new brand Datsun in 2014, which would be a low-cost brand serving customers in the `2-4 lakh price band. Nissan will remain a comparatively premium brand in India. The Japanese company, which exports two-thirds of its production presently from India, is also talking about making India as a larger base for production and exports in the future.

PENTAIR EYES EXPANSION IN INDIA Pentair Inc, one of the leading global water equipment manufacturers, merged with Tyco, a global specialist in valves, controls and thermal management, plans to tap one-fourth of the $2.8-billion water and fluid processing market in India. The merged entity will focus on better technology and marketing of water filtering equipment, pumping & pipeline products and wastewater treatment for both domestic and

industrial sectors. The entity will also double the size of Pentair to $8 billion, increasing its share in all its potential markets, including India. The market for water and fluid processing in India is poised to grow annually by 25% in the domestic arena and 10% in the industrial space due to rapid urbanisation and the felt need to be water efficient. The company’s business grew four times in the past four years in India

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where it mainly manufactures and supplies water filters and filtering systems, water quality control equipment, pipeline systems, valves, pumps and pumping systems. Following this merger, Pentair also hopes to expand its activities in the non-water segment, which is a pipeline for the oil & gas sector, recycling solutions for the power industry and also manufacture pumps and valves for it.

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EVEREST GROUP FORMS PARTNERSHIP WITH KOREA-BASED LOT VACUUM CORPORATION Everest Group has entered into a partnership with LOT Vacuum Corporation, Korea, for developing highly energy-efficient dry vacuum pumps for solar PV, semiconductor, flat panel display & industrial vacuum applications. Amit Kapur, Director Technical, Everest Group, said, “Everest Group has strongly realised and felt the shift of the industry towards green solutions. Strict environmental norms, pollution control, increase in scarcity of water and need for decreasing energy consumption are major challenges of the day and this is what has forced the big industries

to re-think on conventional methods of production and introduce newer and eco-friendly technologies with lower cost of manufacturing. We aim to build the most cost-effective development firm, through the blending of our world-class ‘best practices’ with local experience and knowledge.” “All these translate into opportunities for Everest,” he added. The partnership has introduced six different series of dry vacuum pumps to support the needs of Indian customers. These include the DD105, DD225, LD, HD, GD & GHD series vacuum pumps.

SAFRAN TO BUY GOODRICH’S ELECTRICAL POWER SYSTEMS BUSINESS FOR $401 MN French aerospace firm Safran recently said it has agreed to buy the electrical power systems activities of Goodrich, owned by United Technologies, for around €310 million ($401 million) in cash. Deals in European aerospace and defence are in focus after a proposed $45-billion merger between Airbus parent firm EADS and British defence firm BAE Systems recently collapsed. The Safran transaction is expected to close late in 2012 or early in 2013. It includes the Goodrich division’s 60% stake in Aerolec, a joint venture with Thales. Safran said Goodrich operations were expected to generate revenues of over $200 million in 2012, of which the aftermarket business should contribute half.

NANOTECHNOLOGY KEY TO ENSURE COMPETITIVENESS IN DEFENCE SERVICES As part of the initiatives to further promote and strengthen the use of nanotechnology in various defence applications, Defence Research & Development Organisation (DRDO) conducted a ‘Workshop on Nano Technology for Defence Applications.’ DRDO has initiated R&D in the area of nanoscience and technology and nearly half of its laboratories already have programmes in this important area. The laboratories of DRDO further has plans to shape nanotechnology projects and proceed as other transforming technologies such as chemistry, steam power, and electricity and electronics and information technology. “Nanotechnology is an emerging field, which can lead to the

development of new weapon systems and products that can benefit our nation,” said Hon’ble Defence Minister of India AK Antony recently. Further, he complimented DRDO for taking up nanotechnology mission for defence applications and said, “There is a need to adopt a conglomerate, or consortium approach that involves academic institutions and industries.” In addition, Dr Vijay Kumar Saraswat, Scientific Advisor to the Raksha Mantri, Secretary, Department of Defence R&D and DG DRDO, said, “Nanotechnology should lead to higher protection, more lethality, longer endurance and better selfsupporting capacities of future combat soldiers.”

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

UNFAVOURABLE ECONOMIC CONDITIONS TO PULL DOWN INDIA’S STEEL CONSUMPTION Unfavourable domestic and external economic conditions are set to pull down India’s steel consumption in the current calendar year due to a steep decline in manufacturing and construction activities. The World Steel Association (WSA), a body representing 170 countries of steel producers and consumers, has lowered its steel consumption forecast in India to 5.5% at 73.6 million tonne for the calendar year 2012 from 6.9% growth estimates the Association had made in April this year. For 2013, however, the Association has forecast steel demand to grow in India at 5% 77.3 million tonne. The steel demand had recorded 4.9% growth in 2011 at 67.8 million tonne from 64.9 million tonne in the previous year. The cut in steel consumption growth is based on the ongoing unfavourable conditions across manufacturing and housing sector that have been reeling under unprecedented slowdown for the past few years. India’s manufacturing activity growth remained steady in September as well due to increase in export demand and industrial output. The HSBC compiled manufacturing purchasing managers’ index (PMI), an important parameter to judge the performance of the sector, remained steady. Same is the case with the construction sector. The two sectors consume around 55% of India’s steel production. While presenting a short range outlook for 2012 and 2013, WSA forecasts global apparent steel use to increase by 2.1% in 2012, which is considerably lower than the 6.2% growth achieved in 2011. In 2013 world steel demand will grow by 3.2% and reach a record high of 1,455 million tonne.

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EXPORT PACKAGE

Developing Industry Through

EXP

RTS

India’s exports have fallen due to low levels of demand, especially from Europe and the US—the country’s major export markets. However, given the current ﬁscal position of the government and the country’s budget constraints, huge expectations from the export package may not be appropriate. At the same time, the industry expects the government to extend interest subvention to all critical sectors of exports, particularly leather, gems & jewellery, auto components, pharmaceuticals, etc. While earlier, in June, the government had announced a `1,600-crore package for the export industry, it may soon announce another package in order to encourage Indian exports. ARINDAM GHOSH

ecently, World Trade Organisation (WTO) lowered its projection in the growth of international trade for the current year to 2.5% from the previous estimate of 3.7%. The prevailing Eurozone crisis and uncertainty in the global markets has heavily hit the demand levels. In the process, growth of exports has taken a dip. Given the rising levels of globalisation, India’s exports have been severely affected. The European Union (EU) and the US together consume more than one-fourth of India’s exports. However, the country’s exports have fallen by 5.9% year-on-year in the first five months of the present fiscal year (2012–13). To support exports, the Government of India may launch an export package. The move is expected to bring some relief to the community. Earlier in June, the government launched `1,600-crore package for exporters.

EXPECTATIONS FROM EXPORT PACKAGE The package may benefit those industry verticals that have been hit hard due to low levels of exports. M Rafeeque Ahmed, President, Federation of Indian Export Organisations (FIEO), says, “We are conscious of the fiscal

position of the government, and, thus, I do not expect a big bang package for exports. However, I expect the government to extend interest subvention to all sectors of exports, especially to leather, gems & jewellery, auto components, pharmaceuticals, etc. We feel there is a need to support products that have not done well in exports in the April–August period. The focus should be on providing marketing support to MSMEs so that they continue their market presence during economic contraction as well so as to reap good dividends when the global situation improves.”

SECTORS AFFECTED Some of the industry verticals under the manufacturing sector have been hit heavily by the economic slowdown, which has set a target to contribute 25% to the country’s GDP by 2020. Pointing out the sectors that have been affected by the slowdown in demand, Ahmed says, “In the manufacturing sector, the worst hit is engineering, which has the largest share in the country’s exports. The slowdown in the EU and other economies has an adverse impact on car sales that has impacted our auto component industry.” The sluggish real estate has slowed down construction equipment exports. He adds, “The exports of

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diamond and its jewellery have been affected, but gold jewellery is doing well because of its intrinsic value. Also, the textile sector, particularly apparel, is facing competition from Bangladesh, Sri Lanka, Vietnam and Turkey. ”

STEPS THAT NEED TO BE TAKEN India’s exports will touch $450 billion by 2014. The Engineering Export Promotion Council has set a target of tripling engineering exports to $120 billion by 2015. However, the cost of credit is the key to manufacturing and exports. The interest cost in India is quite high, which adversely affects the industry’s competitiveness. A general reduction in interest would be most desirable, particularly when inflation is softening. It is equally important to separate exports from rising interest rates. Suggesting steps to benefit the exporters, Ahmed says, “Exports require a level-playing field. It means that the credit should be available at internationally benchmarked rate, which is near 5%. However, if it cannot be provided at 5%, we may provide export credit at 7%. With the rupee appreciating, we are loosing exchange advantage and thus special & differential treatment for export is the need of the hour.” arindam.ghosh@network18publishing.com

POWER PROBLEMS

A Roadblock in India’s growth story A study conducted by ASSOCHAM reveals that a massive 80% of coal-based power projects in the private sector are far behind schedule. This scenario has arisen primarily owing to the huge number of regulatory clearances. But this is not all! This situation is further complicated by the fact that the 20% projects, which are on schedule, may also get delayed if the issues related to uncertainty over coal linkages and policy frameworks are not resolved at the earliest. ARINDAM GHOSH

confidence, such delays in regulatory concerns to be cleared of such as f the total capacity approvals may further hurt the environment approvals. addition to be achieved confidence of investors. And with India The government is making efforts by the private sector aiming to become the second-largest to promote the adoption of green projects, only about economy after China in the next 40 technologies in the manufacturing 7,000 MW will be years, such delays will hamper the process. Government initiatives such commissioned on time. For the progress of country’s ambitious targets. as concession on import duty for remaining 44,000 MW of capacity certain wind turbine parts have proved addition planned in the 11th Plan, to be a boon for the renewable energy there could be long delay. According DEVELOPING RENEWABLE ENERGY sector. Further, the policy regulators to Rajkumar N Dhoot, President, The power sector, both in the are working towards introducing ASSOCHAM, “This is rather bad generation and distribution segments, eco-friendly policies in the form of news, especially when India is a ‘big continues to suffer from several subsidies, tax concessions, energy-deficit country’, the fiscal incentives, etc. In industrial production is Unless large-scale reforms are carried out with a strong addition, India boasts of down and investment political will, the power infrastructure of the country will not one of the world’s largest sentiment is weak.” improve. Even after several programmes like Accelerated programmes for developing Except for a handful Power Development Reforms Programme (APDRP) and renewable energy. The of projects promoted Restructured ARDP, several states including several big ones government has launched by big industrial and have a very high degree of T&D losses. Jawaharlal Nehru National corporate houses such as Solar Mission, under which the the Tata Group, Reliance Power, OP inadequacies, such as low level of government aims to develop 20,000 Jindal Group and Indiabulls Group, plant load factor and high level of MW of solar power by 2022. most of the projects are running transmission & distribution (T&D) As a result of these initiatives taken behind schedule. Since the country is losses. Then, there are issues such as by the government, investment in the currently not enjoying strong investor coal linkages and a maze of regulatory

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POWER PROBLEMS

very high degree of T&D losses. For renewable energy sector has become a timely work being undertaken by instance, Jammu and Kashmir had as possible choice. The entry of the private Tata Power’s Mundra Ultra Mega high as 73% T&D losses in 2010–11, players in this sector has also created Power Project (UMPP) in Gujarat, while Uttar Pradesh had 40%. The immense opportunities. Elaborating Indiabulls’ Amravati Thermal Power ASSOCHAM study also points out, further, DV Giri, Secretary General, Project in Maharashtra and Reliance “It is thus no surprise that bankers are IWTMA, explains, “With most of the Power’s Sasan UMPP in Madhya also becoming wary of financing power power projects based on conventional Pradesh. While these projects would projects, given the policy uncertainty sources running behind schedule, be commissioned in time, the high renewable energy has a cost of coal may prove The government is making efforts to promote the adoption greater role to play both in to be a hindrance. Coal of green technologies in the manufacturing process. helping India achieve its prices have lately seen Government initiatives such as concession on import duty for economic growth targets as a big increase in the certain wind turbine parts have proved to be a boon for the well as addressing its energy domestic as well as renewable energy sector. security concerns.” international markets. and other market risks, including a very The ASSOCHAM study adds, “Under high price of coal in the international these circumstances, we face a big KEY CONSIDERATIONS market.” Introducing a case-to-case challenge of reviving the sector, which T&D loss is a major problem faced flexible policy mechanism based on the can be the engine of the India story. by the power sector. Unless large-scale consideration of important issues, such Without power and electricity, we face reforms are carried out with a strong as land, environment, coal, etc., can a dark and uncertain future, which the political will, the power infrastructure speed up the approvals. country can ill-afford.” Therefore, the of the country will not improve. country needs a flexible and investorEven after several programmes like friendly policy mechanism to help the Accelerated Power Development FLEXIBLE POLICY MECHANISM HOLDS power sector to grow. Reforms Programme (APDRP) and THE KEY Restructured APDRP, several states For the private sector, the only including several big ones have a consolation is the speedy and arindam.ghosh@network18publishing.com

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SEARCH November 2012 Ad Name: MGM Pg No. 47

SEARCH November 2012 Ad Name: Renu Pg No. 48

CUTTING-EDGE SOLUTIONS

SOLAR CELLS MADE FROM BLACK SILICON CONVERT SUNLIGHT INTO ELECTRICITY bout a quarter of the Sun’s spectrum is made up of infrared radiation, which cannot be converted to energy by standard solar cells. Therefore, this heat radiation is lost. One way to overcome this is to use black silicon that absorbs nearly all of the sunlight that hits it, including infrared radiation, and converts it into electricity. “Black silicon is produced by irradiating standard silicon with femtosecond laser pulses under a sulphur-containing atmosphere. This structures the surface & integrates sulphur atoms into the silicon lattice, making the treated

Solar cells made from black silicon

material appear black,” explained Dr Stefan Kontermann, Head – Research Group ‘Nanomaterials USPs for Energy Conversion’, • Black silicon solar cells are specifically Fraunhofer Project designed to absorb the Sun’s spectrum Group for Fiber Optical Sensor Systems, • If manufacturers equip their solar cells with Fraunhofer Institute for this black silicon, it would significantly boost Telecommunications, the cells’ efficiency by enabling them to Heinrich-Hertzutilise the full Sun spectrum. Institut, HHI.

Researchers at HHI have managed to double the efficiency of black silicon solar cells. “We achieved that by modifying the shape of the laser pulse we use to irradiate the silicon,” informed Kontermann. This helped in solving a key problem of black silicon; in normal silicon, infrared light does not have enough energy to excite the electrons into the conduction band and convert them into electricity, but the sulphur incorporated in black silicon forms a kind of intermediate level. In sulphur, this intermediate level not only enables electrons to climb the ‘wall’, it also works in reverse, enabling electrons from the conduction band to jump back via this intermediate level, causing electricity to be lost once again. By modifying the laser pulse that drives sulphur atoms into the atomic lattice, researchers can change the positions of these atoms adopt in the lattice and change the height of their ‘levels’, i.e., their energy level.

NEW PROCESSES ENSURE COST-EFFICIENT SOLAR CELL PRODUCTION by hot wires. “This way, we can use apart the silicon-hydrogen bonds. The raunhofer researchers are almost all of the silane gas, so we now free silicon atoms and the silicondesigning new coating actually recover 85–90% of the hydrogen residues settle on the surface processes and thin layer costly gas. This reduces the overall of the substrate. However, the plasma systems that, if used, could significantly manufacturing costs of the layers by only activates 10–15% of the expensive help to reduce the price of solar cells. over 50%. The price of the wire that silane gas; the remaining 85–90% are The photovoltaic industry is pinning we need for this process is negligible lost, unused. This involves enormous its hopes particularly on highwhen compared to the price of the costs. efficiency solar cells that can achieve silane,” explained Dr Lothar efficiencies of up to 23%. Schäfer, Department Head, These ‘HIT’ (Heterojunction USPs IST. This is possible since with Intrinsic Thin layer) cells • Instead of using plasma, activating the gas by the silicon film grows up at consist of a crystalline silicon hot wires ensures that almost all of the silane the surface about five times absorber with additional thin gas is used, thereby actually recovering faster than with plasma layers of silicon. Until now, 85–90% of the costly gas. This reduces the CVD. Another advantage is manufacturers used the plasmaoverall manufacturing costs of the layers by that the system technology is CVD (Chemical Vapour over 50%. much easier than with plasma Deposition) process to apply • The price of the wire that is needed for this CVD. Therefore, the system these layers to the substrate— process is negligible when compared to the is substantially cheaper. Thus, the reaction chamber is filled price of the silane. for example, the generator that with silane (the molecules of produces the electric current this gas are composed of one to heat the wires only costs around Researchers at IST have now silicon and four hydrogen atoms) and one-tenth that of its counterpart in the replaced this process—instead of with the crystalline silicon substrate. plasma–CVD process. using plasma, they activate the gas Plasma activates the gas, thus breaking

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CUTTING-EDGE SOLUTIONS

NEW TECHNOLOGY LEADS TO FUEL SAVING IN COMBUSTION ENGINES However, thermal distortion presents USP difficulties since it has not been

n engine without oil will not survive for very long. Pistons need plenty of lubricant to move within the cylindrical sleeves in the engine block. Two things are known to raise the resultant level of friction. First, distortion of the cylindrical bore hole when the cylinder head is attached, called ‘static distortion’. Second, when the engine runs and temperatures warp the bore hole. The extent of this thermal distortion depends on prevailing engine temperatures & the engine model. In reality, the piston does not follow a perfectly smooth up & down motion; instead, it touches at points within the bore hole. This results in the engine requiring a great deal of oil & gas. Automakers can compensate static distortion. During the final machining stage, honing, technicians mount a honing liner to the engine that simulates the cylinder head that will later be mounted. Only then the work on the bore hole is completed.

possible to compensate for this effect. This problem has now been solved by researchers at the Fraunhofer Institute for Machine Tools and Forming Technology IWU in collaboration with a car manufacturer and a machine tool producer. Researchers start by working

This technology makes it possible to compensate for both static and thermal distortion

out how an engine block is likely to become distorted; they determine the level of static distortion by unscrewing the cylinder head & measuring the extent to which the bore hole has been warped. They then simulate thermal

The new technology will lower the high cost of ﬁlling up your car, by enabling combustion engines to consume 2–3% less gas and signiﬁcantly less oil, while eliminating a step in engine production.

distortion that occurs in each engine series, using an operating temperature of 900 Celsius as their reference. The honing tool adjusts its shape based on these calculations, altering the profile of the bore hole so that motions of the piston are perfectly smooth when the engine runs, preventing excessive friction. Researchers have integrated small Piezo actuators in the tool, which alter its shape & expand the diameter as required. “This is how we can incorporate any ‘imperfections’ in the otherwise perfectly round shape of the finished bore hole,” says André Bucht, Head of Department, IWU.

HEAT-CONDUCTING COMPOSITES FOR SEAWATER DESALINATION

here are vast quantities of seawater available; drinking water, on the other hand, is scarce. Desalination plants can convert seawater into drinking water. These plants require pipelines made of a special kind of steel or titanium— expensive material that is becoming increasingly difficult to procure. Heatconducting polymer composites may soon replace titanium altogether. Drinking water is a scarce commodity. As a result, industrial plants that can desalinate seawater and convert it to drinking water are on the rise. Here’s how the principle of desalination works: seawater is sprayed on pipes heated by pumping hot gas or hot water through them. Pure water evaporates from the seawater, leaving a salty sludge behind. This process subjects the material and its properties

to a diverse array of demands: the material from which the pipes are made must conduct heat and be particularly robust in resisting corrosion and the formation of deposits, and these

USPs • The polymer composites are a plastic, and yet they conduct heat. • They can be produced in continuous lengths and are correspondingly more economical than their metal counterparts. properties must be durable over a long period of time. And for the water to evaporate properly, the piping must also be easily coated with seawater. This is why manufacturers to date

have used only titanium and high-alloy forms of steel, which are very costly. Researchers at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Bremen are developing an alternative to titanium tubes: pipelines made of polymer composites. Polymer composites are a plastic, and yet conduct heat. Another benefit: they can be produced in continuous lengths and are correspondingly more economical than their metal counterparts. But what did researchers do to make a polymer heatconducting? “We introduced metal particles into the material—or more precisely, we add up to 50% copper microfibers by volume. This does not change the processing properties of the composite, and it can still be processed as any other polymer would,” noted Arne Haberkorn, Scientist, IFAM. Courtesy: Fraunhofer

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JG KULKARNI, PRESIDENT, IEEMA

Think Global is going to be a

Survival

strategy

“Export in India is not going to be a growth strategy; it would be a survival strategy,” avers JG Kulkarni, EVP, CG, who has been recently appointed as President, Indian Electrical & Electronics Manufacturers’ Association (IEEMA), during a tête-àtête with Prateek Sur. Kulkarni has been associated with Crompton Greaves for the last 32 years and is also the President of CG Power (Asia). He has worked in various disciplines individually and jointly with international experts in design, technology, projects, quality systems, TQM-BPR-TOC. With a Masters in Electrical Engineering from the Indian Institute of Science, Bangalore, Kulkarni has donned various roles including Member on Board of CG Lucy Switchgear Ltd and CG-ZIV Power Automation Solutions Ltd. In addition to his business responsibility, Kulkarni also handles various processes in HR, Technology and Business Excellence and is actively involved in various national and international forums for promoting the Indian industry. Excerpts...

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JG KULKARNI, PRESIDENT, IEEMA

Power sector is the lifeline of a country’s economic growth. Even after taking various measures, the industrial scenario in many parts of the country remains dismal due to power shortages. What are the measures that the government and industry should take to eradicate this ever-increasing power demand-supply gap? Everyone in the nation should have 24X7 access to power, but this is not the reality. The availability of power depends on the ability of user industries to distribute power to the users. Power shortage is a cause for concern. The investment proportion in the three specific categories of power, viz., generation, transmission and distribution, should ideally be 2:1:2. According to the 11th Commission Plan, there is 55% investment in generation, 15% in transmission and 30% in distribution. Even though the 12th Plan has made some amendments, the ratio is still not 2:1:2. According to recent announcements, if a good amount of money is spent on discoms, it would not only better the proportion ratio, but would also cut short the wastage. Also, apart from generation of power, sufficient funds should be spent on distribution.

Many reforms have been implemented and age old policies have been eradicated in the recent past. What, according to you, have been the major breakthroughs when you analyse the situation specifically in terms of electrical equipment? The recent restructuring of policies for discoms is in itself a big breakthrough; but this is subject to its success. While at the policy level, this is a good breakthrough, we have to see and check for ourselves how successful it becomes.

Power theft has been one of the major issues hampering the growth of the sector. What measures should the industry and government take to root out this critical concern? Distribution contributes the maximum with regards to power theft as there cannot be any theft during generation. The theft rate can never become zero, but it has to be minimised. For this, discoms will have to take initiatives such as upgrade their technology in such a manner that it can distribute power without incurring any losses. Hence, the distribution has to become more localised. This can be achieved by increasing the number of power stations where the power is brought down from a higher level to a lesser value and then allotted for public consumption. Similar measures can be taken to reduce thefts. Additionally, theft is an attitude that has to be dealt with in a more mature manner. A poor guy stealing is understandable, but not tolerable. However, if people who can afford to pay also follow similar practices without paying for using power, then authorities need to mete out stringent punishment to these offenders. Possibly then, such thefts will reduce. Besides this, using technologies like electronic meters would help as they cannot be tampered with.

You recently stated that the financial distress in the power distribution sector has been negatively impacting the Indian electrical industry. Kindly elaborate on the same giving a perspective on the recent development of ‘Financial Reforms & Policies for Discoms’...

According to data, the cumulative loss of all discoms till March 2011 is `1.95 lakh crore—a clear indicator of unhealthy management. The health of UP CLOSE & PERSONAL an organisation is accounted for by the Accomplished Achievement amount of money it makes and whether Helping CG make profits and become it is usefully utilising that money in a leader. innovation and R&D. If discoms get Your comment on Indian electrical Tips to scale up business for SMEs money, then rather than innovations manufacturers’ design and technical Go global and expand beyond India. and R&D, paying off the employees’ competency… salaries and clearing all the dues will The $22 billion electrical industry in be on the priorities’ list. But on the flip side, if a company India is mature. The country has technological capabilities cannot invest in R&D and innovations, then it will not be that have been well demonstrated by big players. Moreover, able to come out of the financial distress. The health of an big industries have developed their R&D base and organisation can be understood by how healthy its customers technology. However, it is imperative for them to look into are. In state-owned discoms, money is never lost, even though transmission and distribution effectively. Also, these big there may be uncertainty over the fact as to when the money players in India are among the best in the world when we will be received. Thus, most companies like to do business consider technology, capability and innovation, among other with discoms even if it means ending up in heavy debts factors. However, there is possibly a lack of innovation and considering that the returns would be received after, say R&D in the lower scale companies and SMEs. If these about, 150–180 days or even more. If this is done away with, smaller industries work towards increasing their R&D and then the performance will improve. This, in turn, will increase innovation capabilities, then India would be poised at a high the demand and help companies come out of financial stress. level among the world players.

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JG KULKARNI, PRESIDENT, IEEMA

Uplifting the competitiveness quotient of SMEs in this space is also one of the primary objectives to achieve holistic growth. How are you planning to harness the same? Financial reforms will have an effect on discoms. This, in turn, would generate the market, which is, in most cases, catered to by SMEs. As a result, distribution will receive a boost as discoms are generally held by SMEs. The more SMEs manage to attract investment owing to financial reforms, the more they would be able to generate market for small and medium-sized industries. By doing so, the health of discoms would get better and erosion in the price level will be done away with. Besides, the right quality of products would come up and optimised designs would also be used. All these would be key for SMEs to be working on.

India would be demanding in terms of quality & health and safety & environment and so on. Thus, going global would help industries work themselves up and better themselves so that they could meet the global standards.

Skill enhancement is also one of the major agendas that the industry needs to deal with in order to bring in competency. What’s your take on the same? Also, enlighten us on the practices that you have implemented at CG for nurturing skill development.

India is likely to witness a shortage in skilled manpower in future. To tackle this, many companies have started taking initiatives like sector skill improvement initiative. IEEMA is partnering with many such organisations to hone the skills of manpower for SMEs and discoms. Many electrical industries have partnered with ITI for skill development and are making Going by the global market sentiments, exports have been sure that the manpower is abreast with the needs of the witnessing major setbacks in the recent past. How has been electrical industry. They are co-coordinating with the industry the scenario when it comes of electrical equipment? What, so that the labour that comes to the industry after training at the according to you, is the need of the hour? ITI would have knowledge Today, export from of all the nitty-gritty of the India is to the amount The announcement by the government of the package on industry. These initiatives of `30,000 crore which ‘Financial Restructuring of Discoms’ will very positively are also supported by the is approximately US$4 impact the entire power sector as the entire power sector value chain crucially hinges on the ﬁnancial viability of the sector skill improvement, billion. The global market power distribution sector, which has been severely eroded in which IEEMA is actively for electrical equipment the last few years. promoting. I think this is worth US$453 billion. would definitely boost skill Thus, India is just a 1% development among the people. share of the global market and any major happenings on the global front would not have any impact on the 1%. However, if this is a 20% market share, then it would have an impact on Going by the recent announcements, the heavy industries everything. Thus, according to my understanding, what we department will come out with a 10-year vision plan for are doing in terms of exports from India is negligible. Unless electrical equipment manufacturing industry in a couple of this negligible is converted into a good-enough percentage, if months. What is your wish list from the same? not a significant one, nothing is going to happen. According This mission plan is a co-creation between IEEMA and to me, this should go up to 4–5% at least. The motivation the Department of Heavy Industries. This also involves for all players in the electrical industry should be to ‘Go active participation from E&Y. We were together able to Global’. IEEMA, along with the others in the industry, is come up with a document which would be released very emphasising on the ‘Go Global’ theme even in events like shortly. That document would aptly define the needs and Elecrama and is trying to help SMEs to expand globally. steps that should be taken by the industry. There are five different work groups which are being formed to guide and According to my knowledge, in India, export is not help industries to do what is necessary. This would help the going to be a growth strategy; rather, it would be a survival growth of the electrical industry and also help in meeting strategy. If companies do not export, then they would exports demands to an international level. not stand a chance in the coming years. Foreign players are looking at India as a potential ‘big’ market and thus, export has to be done by Indian industries. The start should What is going to be your prime agenda in your position as not be in huge amounts, as exports have a lot of risks President of IEEMA? involved. Going global is going to be a survival strategy for any The ideal start up ratio should be 70% domestic market industry. So, IEEMA would help towards that goal. Thus, and 30% exports. If this is worked upon, then there will as President of IEEMA, my prime agenda would be to help be good profits for companies and India would slowly start industries think global and thus help them to increase their making its mark in the international market. This would exports and go global. improve the financial health apart from enhancing the operational efficiency considering that customers outside prateek.sur@network18publishing.com

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PAINTS, COATINGS & POLISHES

Indian Paint Industry: Market Watch

According to Indian Paint Association (IPA), during 2011–12, the Indian paint industry— estimated at `29,000 crore—had achieved a volume growth of nearly 12% and value growth of about 22%. But in the current year, 2012–13, the volume growth could shrink to just 8%, while the value growth may come down to 15%. Riding high on the demand from infrastructure, industrial, automotive and decorative sectors, the Indian paint industry continues to enjoy a healthy growth rate as compared to other economies and, based on the same, it is anticipated that the sector will post a CAGR of around 15% during FY2012 to FY2015.

Challenges

The challenges are primarily due to raw material availability, their rate fluctuation, lack of quality in many cases and dependency on third-party formulation. These, if not handled accordingly, can affect the industry’s growth trajectory.

BASF Coating has been awarded ‘Supplier of the year’ by GM for the eighth time. This boosts BASF’s step of introducing environment-friendly CathoGuard® 800 and 900 product line—a cathodic e-coating system that provides the base for automotive surfaces and protects edges and cavities from corrosion. Leading specialty chemicals manufacturer, Rhodia, recently announced the launch of Rhodia Coating’s storefront on the SpecialChem website. Leveraging SpecialChem’s global online marketing platform, Rhodia’s storefront will help the company connect with paint and coatings customers worldwide providing customers with the most updated information on innovative products, sustainable solutions and technical expertise. After experiencing a standstill growth for the first time in 20 years, Asia’s leading manufacturer is now planning to target China’s low-income house building programme—a mammoth government-backed project. InnoVoc Solutions, a division of Gordon Composites, Inc., recently announced the availability of breakthrough technology for powder coating plastics, composites and other non-conductive substrates. The technology makes non-metallic substrates temporarily conductive using a surface treatment that emits no Volatile Organic Compounds (VOCs) or other hazardous byproducts. The ever-expanding Dow Chemical Co. will invest in a new manufacturing facility for its Dow Coating Materials business unit in Saudi Arabia. Investment in the new facility is intended to support growth in the region and allow Dow to tailor innovation to the region’s needs. RPM International Inc. recently announced that its Rust-Oleum Group has acquired HiChem Paint Technologies Pty. Ltd., a leading Australian manufacturer of automotive aftermarket coatings, as well as specialty coatings for industrial applications and home maintenance.

Players

All the international bigwigs have their presence in India. The major players in the paint market are Asian Paints, AkzoNobel, PPG, Henkel, Nippon Paint, Dow Chemicals, DuPont, Prowax, BASF, Kansai Paint and Berger Paints.

In the News

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Compiled by Suprita Anupam

PAINTS, COATINGS & POLISHES

PAINTS’ SELECTION CRITERIA: Decoding Material Formulation .................................................58 CORROSION-RESISTANT COATINGS: ‘Coat’ To Keep Corrosion Away .....................................62 NEW-AGE PAINTS AND POLISHES: Offering Manufacturers A Hue Of Productivity ...................68 ERP FOR PAINTS INDUSTRY: Stock It Right! .................................................................................70 INDUSTRIAL APPLICATIONS: Integrating Aesthetics With Durability ..........................................74 INDUSTRIAL PAINTS & POLISHES: Designing The World Beyond Imagination ............................76

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PAINTS’ SELECTION CRITERIA

SUPRITA ANUPAM

rom the oil paints (developed in 12 th century), beeswax mixed with hard animal fats, carnauba wax to the water-resistant and heat-resistant synthetic polymers, paints and polishes are a part of surface coating. Over the years, these have changed a lot, be it—polymer, pigment, solvent or emulsification formulations. In the last few decades, many blends of carnauba with ouricui, candelilla, esparto, sugarcane, cotton fibre, flax, palm, hemp and raffia waxes have been developed as costeffective polish materials. Simultaneously, the petroleum industry has yielded a number of raw materials, which are used in various polish formulations including paraffin waxes with varying hardness & melting points and inexpensive solvents such as kerosene & naphtha. Nowadays, synthetic polymer

much more application specific. Various resins or polymers have been developed as per their binding capability, solvent by their film-formation capability, surfactant by their stabilising ability, pigments by colour requirement and quality, thickener by viscosity,

Decoding

Material Formulation

both paint formulators and chemists. Nanotechnology can be useful in enhancing many coating properties, especially mar and scratch resistance. However, the implications of using nanomaterials for health and safety are debatable. Since the past few years, titanium dioxide (TiO2) has been used as paint pigments owing to its ability to confer opacity and whiteness to a whole host of different materials. Its high refractive index, ability to absorb UV radiations and nontoxic nature has made TiO2 the best white pigment available. Photo-oxidation tests on paint films show a clear demarcation between nanoparticle and pigmentary grade TiO2. Model system tests on 2-propanol oxidation and hydroxyl analysis show some precise correlations of pigmental activities. It has now been understood that the use of nanoparticle anatase in conjunction with pigmentary grade rutile is a viable option for

Material composition of paints is decided in accordance with the application, cure rate, cost, mechanical properties, durability, anti-oxidation properties and colour requirements. Further, the mixing depends on the polishing agenda, solvents, emulsiﬁers and auxiliary materials, such as preservatives, colourants and fragrance. Here’s taking a look at how the formulation of materials is coded... emulsions have been introduced that offer significant improvements over wax systems. The most widely used polymers are based on silicone oils, which provide lubricity and good gloss. Aerosol spray remains the most popular delivery system for these products, owing to the fact that they offer easy application over a large surface area. In terms of properties, the materials provide ease of application, excellent gloss, wearability, water resistance and heat resistance. Paint materials are more customised in nature and are

anti-foaming agents and additives as per their cost factor and plasticiser. Coal Tar Enamel (CTE) are proactive coatings, while Fusion Bond Epoxy coatings are already very popular in India. Let us take a look at some of the latest materials, polymers and resins developed to improve paint quality, along with their pros and cons.

NANOTITANIA The ability of nanoparticles to destroy bacteria and fungi has been a fascinating subject of interest for

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developing self-cleaning paint surfaces. The anti-bacterial activities of these nanoparticles are inversely proportional to the particles’ size that correlates their intrinsic ability to generate active carriers, thereby giving rise to active surface species. It can be concluded from this that the antibacterial efficiency of TiO2 is not determined by the surface area but by its ability to generate active carriers, resulting eventually in the formation of effective chemical species such as peroxides. Apart from titania, calcium

PAINTS’ SELECTION CRITERIA

and inability to distribute nanotitania carbonate (CaCO3) is also mixed in With EVOQUE™ Pre-Composite uniformly over the film coating, the the film. When mixed, they become Polymer technology, paint formulators hiding efficiency decreases. Instead more active to nitrogen oxide (NOx) can improve the hiding efficiency. of adding more TiO2 which certainly and Volatile Organic Compounds EVOQUE™ Pre-Composite Polymer (VOCs), which leads to the entry of is acrylic-based, and as per tests done adds to the cost factor—Dow Research nitrate compounds into the ecosystem. by Dow Research Labs, it shows scientists have come up with different However, higher levels of TiO2 and excellent exterior durability that can be solutions such as ROPAQUE™ CaCO3 impart lower durability as well further enhanced by removing some of Opaque Polymer and EVOQUE™ as reduce the translucency of paint the TiO2 that participate in some of the Pre-composite Polymers. While films, thereby increasing absorptivity. ROPAQUE™ Opaque Polymer falls chemical processes that degrade films. Developing the right composition of under the same category as TiO2: Commenting on the same, S Ashok nanotitania for the coating purpose is Kalyana, Director – Architectural both are pigments and employ the not an easy task. Marketing, Dow Chemical same fundamental mechanism for Company, North America, describes, providing hiding efficiency in paint. Elaborating further, Ivan Terezzino, “EVOQUE™ Pre-Composite Polymer EVOQUE™ Pre-Composite Polymer Head – Chemical Development, technology can be used alone or along is a completely new class of polymer and Decorlit Construction Solutions, shares, with ROPAQUE™ Opaque Polymers. a completely different way to maximise “I tried using nanotechnology to develop It opens the door to a completely new TiO 2 efficiency. ROPAQUE™ photocatalytic paint and achieved good way of thinking about formulating results. The most difficult part of my Opaque Polymer can cost-effectively more value into your paint products. work was to obtain raw materials that replace up to 20% of TiO2 in satin and Depending on your objectives, your could further improve the results. semi-gloss formulations and up to 35% products & your brand, you can gain Though this resulted in a good product, in high-quality flat formulations. value through one or more of the it was expensive, even without getting following: better hiding with equal technically where I would like to be. HOW DOES ROPAQUE™ OPAQUE or less TiO2, equal hiding with less We lack a better approximation of this POLYMER WORK? technology. However, we can evaluate TiO2, improved barrier properties, ROPAQUE™ Opaque Polymer is the benefits, which will help us in produced with water encapsulated in including stain resistance and removal. adjusting the costs.” Cost is a major a hard polymer shell. Water remains Opportunities to balance higher hiding issue with nanotitania film coatings, inside the shell during paint and improved barrier properties with making it unacceptable for use on a formulation, storage and application. reduced TiO2 usage and lower raw large scale. material costs help in making the As the wet paint film on the substrate formulation you want for your market.” dries, water evaporates. This causes Substantiating the same, the water inside the void to move out Antonio Carlos Veronezi, Chemical of the hard polymer shell. Formulator; Consultant; and Technical OTHER RESINS/POLYMERS Representative, Commercial Paints The hard polymer shell retains its Alkyd Resins and Coatings, avers, “I believe that shape and the remaining void is One of the reasons for using alkyd resins there exists many possibilities to use filled with air, creating a refractive is its successful chemically combining nanotechnologies in paints. However, index differential. capability with oil or oil-derived reducing the cost is a big hurdle. The fatty acids to a polyester polymer The resulting air void scatters light purchasing power of the masses is still structure. The other benefits include by the same mechanism as TiO2 low. For example, in decorative paints, improvement in mechanical properties, and may replace up to 20% of TiO2 it is possible to use nanotechnology on dying speed and durability over the in a satin or semi-gloss paint and up a large scale in a few applications such natural polymer-based coatings. While to 35% in a flat paint. as marine, automotive, aerospace each of the main ingredients of an coatings, electronic paints, etc.” alkyd contributes to its properties Table 1: Some Common Inorganic Pigments in a predictable manner, long oil Pigment Colour(s) alkyds contain over 60% oil content ROPAQUE™ OPAQUE POLYMER Carbon Black Black (expressed as ‘oil length’), medium AND EVOQUE™ PRE-COMPOSITE Titanium Dioxide White Iron Oxides Yellow, Red, Brown, Black oil between 40% and 60%, and POLYMERS Azurite Blue short oil below 40%. As we have seen earlier, Chromium Oxides Green, Blue nanotitania has many advantages Epoxy/Polyepoxide Cadmium Sulphides Greenish Yellow to Red to Bordeaux over conventional resins. Epoxy is a thermosetting polymer Lithopone White However, owing to the cost factor produced from the reaction of

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PAINTS’ SELECTION CRITERIA

in the long term. ABB has stepped and so on. Other positive features an epoxide ‘resin’ with polyamine up its efforts in this regard and has are easy workability, easy to create ‘hardener’. For heavy-duty service on published lists of prohibited as well matching colour tones, high durability metal substrates, two part epoxy coatings as restricted materials. The list of and colour stability that can last up to have been developed that use less energy prohibited materials contains those two decades. than heat-cured powder coatings. They substances that must not be used, while are primarily used for factory cast iron, Starlite the list of restricted materials contains cast steel, cast aluminium applications There is a very interesting story those that a paint manufacturer must because of its low volatility and water behind the rise and fall of Starlite as take care of with its limited/restricted clean up advantages. They are also used a coating material. Starlite is a heatuse. Some of the substances that must in industrial, automotive and decorative resistant super material that could not be used are 1,2-dichloroethane, applications since they are more heat have changed the coating industry 2-ethoxyethanol, 2-ethoxyethyl resistant than latex-based and acetate, 1-methyl-2-pyrrolidone alkyd-based paints. However, Table 2: Some Common Classes of Organic and trichloroethylene as solvent, epoxy paints tend to deteriorate Pigments Group Example 2-metoxyethyl acetate as due to UV exposure, known as Azo Dyes paints lacquers, 2,2’-dichlorochalk out. Monoazo Arylamide Yellow (PY 73) (1 2 3 4 5)* 4,4’-methylenedianiline as Omadine® Antimicrobial Diazo Diarylide Yellow (1 2 3 4 6) hardener in resins and polymers, Lonza’s Omadine® Antimicrobial Barium Red 2B Toner (PR 48.1) (1 2 3 4) Azo Salt 4-(1,1,3,3-tetramethylbutyl) products, part of Lonza Microbial Azo-metal Complex Nickel Azo Yellow (PG10) (1 3 7) phenol as varnish and paints, Control’s Material Protection Polycyclic Pigments and so on. portfolio, are anti-fouling agents Phthalocyanide Copper Phthalocyanine (6 7 ) for use on ships’ hulls and in Anthraquinone Dibrom Anthanthrone (1 2 3 4 5 6 7) protective coatings on nets used BIODEGRADABILITY: A MAJOR Quinacridone Quinacridone Red (PV 19) (1 3 5) in fish farms. In addition to CONCERN Dioxazine Dioxane Violet PV23 (5) copper Omadine® Antimicrobial, In spite of all the efforts Thioindigo Tetrachloro Thiondigo (PR 88) (5) the company’s anti-fouling paint made to improve the material, *Colour Code: 1 = Yellow; 2 = Orange; 3 = Red; 4 = Brown; product line also includes the zinc anti-oxidation properties 5 = Violet; 6 = Blue; 7 = Green Omadine® Antimicrobial as well and anti-bacterial strengths, as self-polishing polymer technology biodegradability of the materials has forever. However, the inventor of the and products. All of these are supported been the constant focus for further material, Maurice Ward died, taking with robust toxicology and regulatory improving material composition, all the formulations to his grave. In the data & approvals all over the world. selection and composite properties. tests, the material could sustain high According to Robert Martin, Global Despite having the multi-layered heat around 1,000°C and the material Strategic Marketing Manager, Lonza coating with the best of polishing, coated would barely warm up. It was Microbial Control, “Many of the new the painted surfaces undergo damage speculated that the material was made self-polishing paints contain copper or decolourisation due to natural up of 21 ingredients; however, no one Omadine® Antimicrobial, the most weathering and growth & activity of knows the exact composition. The widely used co-biocide in the world for living organisms. Micro-organisms success of Starlite was because of the marine antifouling paint applications.” (bacteria, fungi, algae & protozoa) are array of ‘small voids’ between two and primarily responsible for paint spoilage. five micrometres wide on the surface Alesta®PU:Polyurethanne Biodegradability poses major threats of the Starlite, which gave it insulation Alesta®PU:Polyurethanne is one of the to the industries owing to the lack of and lowered its thermal conductivity. innovative Alesta Anodic Collections information on paint materials relevant Restricted Materials developed by DuPont Coating Solutions to their conservation. This indicates Over the years, it was realised that that combines the elegant matte design further need to continue R&D with a cost-effectiveness and performance and brilliant cooler effects of traditional collaborative effort of civil engineers, cannot be the only criteria of material anodised surfaces with the advantages of building conservators, conservation selection. Environmental concerns and an environmentally compatible powder scientists and material manufacturers safety measures must play an equally coating. The patented Qualicoat and and polymer/resin formulators. important role in the selection and GSB-certified powder coating is just rejection. Based on these measures, like all other powder coatings; it is industries have banned some materials adjustable to the application and allows suprita.anupam@network18publishing.com that they found harmful to the users to coat various surfaces such as With inputs from Dow Chemical Company environment as well as human beings aluminium, steel, panels, metal sheets and Indian Journal of Science and Technology

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CORROSION-RESISTANT COATINGS

‘Coat’ to keep corrosion away Corrosion resistant coatings can increase the lifespan of a machine’s component, as well as reduce maintenance and replacement costs. In order to select an appropriate coating, it is important to identify what kind of corrosion a particular part is prone to. The kind of corrosion differs based on how a part is used and what conditions it is exposed to. Using the right coatings and taking measures to preserve the coating for a longer time will increase the lifespan of a machine, which, in turn, will help a business generate additional proﬁts.

NISHI RATH

normally unreachable by a gas flowing orrosion leads to great loss SELECTION OF COATINGS through the components, such as gas in industrial applications, Using low Volatile Organic Compound flow regulators in microelectronic especially under extreme (VOC) materials, such as paints and fabrication. While the industry is conditions, like corrosive coatings, not only decreases the risk doing its best to deal with corrosion, atmosphere and high of corrosion, but also helps reduce there are a few points that need to temperature. To tackle corrosion, carbon emissions. Corrosion-resistant be kept in mind before selecting the corrosion-resistant coatings have coatings for metals vary depending on method of coating. attracted attention for many years the kind of metal involved and the due to its simplicity and efficiency. kind of corrosion prevention needed. Commenting on the same, According to an industry expert, To prevent galvanic corrosion in Himanshu Shah, Director, Red Line “Formerly, cadmium plating, because iron and steel alloys, coatings made Industries Limited, says, “Corrosion is of its good corrosion resistance and from zinc and aluminium are helpful. primarily a chemical reaction between lubricity, was widely used to protect Large components, such as bridges the metal and oxygen in the air. steel workpieces from and energy windmills, are Rising demand from the Asia-Paciﬁc region, especially from corrosion. However, often treated with zinc China and India, are expected to be the major demand drivers for and aluminium corrosionenvironmental issues have the global industrial coatings market. A spurt in manufacturing restricted the usage of resistant coatings as they growth will act as a growth driver for this industry. cadmium in recent times, provide reliable long-term as it is considered toxic.” corrosion prevention. Steel & iron Heat promotes and accelerates this This has led to the need for fasteners, threaded fasteners, and process. Hence, anything that creates developing materials to replace the bolts are often coated with a thin a barrier between the metal and air toxic elements in traditional coatings. layer of cadmium, which helps block would prevent (or at least delay) Industry insiders say that it is preferred hydrogen absorption that can lead to corrosion. Coating, which comes in to form a film only in a specific stress cracking. many forms, is a skin-cover to the region to be exposed to the corrosive The coating system must protect metal and hence, prevents air from environments. Also, there is a need for against water or corrosives for long coming in contact with the metal, forming the coating at areas inside the periods. Also, highly permeable thereby preventing the chemical components apart from areas that are coatings allow corrosion to start reaction known as corrosion.”

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CORROSION-RESISTANT COATINGS

behind the coating even in the absence of breaks or pinholes. Therefore, while selecting a coating, take into consideration the temperature and abrasion resistance and a service rating for water immersion. Apart from that, while selecting coatings to prevent galvanic corrosion, it is advisable to keep in mind some basic facts about the metals such as: With increase in temperature, there is a chance of reversal in the polarity of galvanic couples Salts carried into insulation and deposited onto surfaces interfere/ destroy, the effectiveness of corrosion inhibitors The insulation system is not freely ventilated and may have inadequate oxygen for sacrificial reactions to occur. Though there are various methods adopted by different companies for coating, some of them stand out owing to their advantages over the others.

WIDELY USED FORMS OF COATING According to Shah, “Coatings come in many forms—a plastic-on-metal or a metal-on-metal coat. Plastic on metal coats are popularly called liquid paints or powder coats and metal-on-metal coats are known generally as platings.” Plastic coats This creates an inert surface to prevent the oxygen from coming in contact with the metal beneath. The quality of this coat and the usage of the part (which is coated) would decide the coat’s ‘life’. Parts or products, which require a super-high gloss or are extremely unwieldy, are still liquid painted. With major strides in coating technology today, a vast majority of ‘painting’ is powder coating. - Powder coating: This uses special formulations based on plastic resins like epoxies, polyesters, nylons, polyurethanes, etc. The process involves electrostatically charging and subsequently, spraying the powder on the metal surface and then curing

this powder at high temperature (around 2000C) to get the tough cross-linked powder coat that is impervious to the atmosphere. Powder coats are usually 60–100 microns thick. - Liquid painting: A variety of liquid paints are available to suit specific end-uses of the products being painted. Liquid paints are usually sprayed on or the part is dipped in a vat of charged liquid paint. Drying may be at room temperature or at a somewhat higher temperature like 120– 1300C. Liquid paint coating may not be as tough and durable as powder coat, but it offers a convenient option. These coats are usually 15–30 microns thick. Plating Plating is an electro-deposition on one kind of metal on another kind of metal. Usually, the plating metal does not react with the oxygen in the air, but even if it does, the process is extremely slow. The most common types of plating are zinc plating, nickel plating and chrome plating. These are listed in the ascending order cost and life. Plating coats may be as thin as a

few microns or max 10–12 microns.

METHODS OF COATING There are various methods that companies use for coating. Some of the commonly used ones include: • Galvanising: This is the most widely used metallic coating method for corrosion protection. It involves the application of metallic zinc to carbon steel for corrosion control purposes. Hotdip galvanising, which consists of dipping the steel into a bath of molten zinc, is the most common process. • Nansulate: This is a nanotechnology-based line of liquid insulation coatings, which also provide corrosion prevention, resistance to mold & moisture, flame and chemical resistance and lead encapsulation. They are green and contain low VOC. This sustainable coating line is unique and provides solutions across all customer market sectors. According to experts, Nansulate insulating products have helped companies reduce their overall energy costs. This

ADVANTAGES OF POWDER COATING OVER LIQUID COATING Since the last couple of years, there has been an ongoing debate about ‘which is better’, powder coating or the traditional liquid coating? Taking into consideration the industry opinion and experts views, it can be said that powder coating definitely has an edge over the traditional liquid coating. Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main difference between a conventional liquid paint and a powder coating is that the powder coating does not require a solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically applied electrostatically and is then cured under heat to allow it to flow and form a skin. The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. There are several advantages of powder coating over conventional liquid coatings. These include: Powder coatings emit zero or near zero VOC. Powder coatings can produce much thicker coatings than conventional as compared to liquid coatings. Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% use of the coating. Powder coating production lines produce less hazardous waste than conventional liquid coatings.

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CORROSION-RESISTANT COATINGS

be improved by feeding air to technology, of late, has been Pack Cementation: In this process, the nozzle through a small jet, majorly used in equipment like diffusion coatings are formed by which reduces the pressure in a steam boilers, steam pipes, heat depositing a layer of aluminium on chamber behind the nozzle. This exchangers, industrial ovens, the metal surface and then heating chamber is connected to the brewery equipment, extruders, the component in a furnace for a powder feed hopper. In this way curing containers and water period of time. During this heat a gentle stream of gas is sucked heaters, among others. treatment, the aluminium and metal into the gun and carries powder • Thermal spraying: A group of atoms migrate, or diffuse, into each with it. coating processes in which other—the reason these coatings - Cold Spray: A kinetic spray finely divided metallic or are called diffusion coatings. This process utilising supersonic jets non-metallic materials are processing is usually performed by a of compressed gas to accelerate deposited in a molten or semipack cementation process, in which near-room temperature powder molten condition to form a the aluminium deposition and the particles at ultra-high velocities. coating. The coating material heat treatment occur simultaneously. The unmelted particles, travelling may be in the form of powder, Pack cementation is widely used to at speeds between 500 and 1,500 ceramic-rod, wire, or molten confer oxidation resistance on m/sec plastically deform and materials. Thermal spraying ferrous alloys. Pack cementation consolidate on impact with their can be done using various processes include aluminising, substrate to create a coating. methods like: chromising and siliconising. - Molten Metal Flame Spray: Inorganic Coatings: Inorganic Electroplating: It is the method used Molten metal flame spraying, coatings can be produced by when it comes to finishing designer a thermal spraying process chemical action, with or without items. The process involves applying variation in which the metallic electrical assistance. The treatments a thin layer of metallic material material to be sprayed is in molten change the immediate surface layer onto a base by means of electronic condition. The deposition. The base is Parts or products, which require a super-high gloss or are molten metal process then perforated by a extremely unwieldy, are still liquid painted. With major strides solution and becomes a has advantages in coating technology today, a vast majority of ‘painting’ is and disadvantages. cathode. This process can powder coating. Its advantages be repeated so as to include cheap raw materials; multiply and maximise the layers. of metal into a film of metallic use of inexpensive gases; and oxide or compound that has better gun design is very basic, while corrosion resistance than the natural PROMISING FUTURE its disadvantages are gun is oxide film and provides an effective Industrial coatings are majorly used for cumbersome to use in the manual base or key for supplementary their protective and aesthetic qualities. mode; high maintenance due to protection such as paints. Industrial coatings are extensively used high temperature oxidation and in automotive, steel, construction, Physical Vapour Deposition (PVD): molten metal corrosion; and, marine, furniture, decorative coatings, PVD methods are clean, dry useful only with low melting protective and powder coatings, vacuum deposition methods in temperature metals. among others. Rising demand from which the coating is simultaneously - Powder Flame Spraying: In this the Asia-Pacific region, especially deposited over the entire object. All process, the material to be sprayed from China and India, are expected reactive PVD hard coating processes is in powder form. Powder flame to be the major demand drivers for combine: a method for depositing spraying is probably the simplest the global industrial coatings market. the metal; combination with an of all the spray processes—it A spurt in manufacturing growth will active gas like nitrogen, oxygen, or is done by feeding a powder act as a growth driver for this industry. methane; plasma bombardment of through the centre bore of a Experts say there has been a market the substrate to ensure a dense, nozzle where it melts and is shift towards powder coatings as far as hard coating. PVD methods differ carried by the escaping oxy-fuel the technology is concerned and is set in the means for producing the gases to the workpiece. But this to stay for long. metal vapour and the details of approach yields coatings high in plasma creation. The primary PVD oxides and with void contents methods are ion plating, ion nisi.rath@network18publishing.com approaching 20 volume per cent. implantation, sputtering, and laser (With inputs from International Thermal However, coating quality can surface alloying. Spray Association)

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NEW-AGE PAINTS AND POLISHES

Offering Manufacturers a

Hue of Productivity With the rising level of improvement in the manufacturing processes in terms of increasing efﬁciency and productivity, paints and coatings are increasingly gaining signiﬁcance. Companies are investing heavily on developing new varieties of paints that will enable their customers to enhance the productivity of the production process. As part of the initiatives taken by companies to develop new paints & coatings, companies are coming up with various solutions that are not only highly specialised in their applications, but are also easy to use, economical & safe to handle. ARINDAM GHOSH

Innovation: PRINTEX® Nature Company Name/Developer: Orion Engineered Carbons LLC Features: Orion Engineered Carbons developed PRINTEX® Nature, a new carbon black pigment based on renewable feedstock, such as plant oils (for use in coatings), printing inks and polymer formulations. If the new pigment is combined with natural binder systems and bio-solvents, it is possible to achieve more than 90% sustainable content in a formulation. Its performance is similar to that of traditional carbon black pigments, with colloidal properties that make it ideal for medium jetness and tinting. It can also be used in indirect food contact, where low PAH (Polycyclic Aromatic Hydrocarbon) is necessary. Applications: The company’s carbon black pigments for coatings are used in automotive coatings, high-performance industrial coatings, powder coatings and decorative coatings. They offer a broad product portfolio for masstone and tinting, high-jet products with bluish undertone and excellent UV & weathering performance.

Innovation: Hostavin 3330 disp XP Company Name/Developer: Clariant Features: The solution is an innovative formulation allowing water-borne coatings to achieve the performance of conventional solvent-borne systems. According to the company, Hostavin 3330 disp XP has an active UV absorber content of 52% that brings a significant improvement in the area of UV light protection for water-borne systems. It offers high thermal stability and superior durability for effective prolonged service life, displaying high extinction in the protection of thin layers. Applications: Hostavin 3330 disp XP is ideal for use in clear and pigmented coatings for exterior wood protection as well as for industrial and automotive coatings. New Hostavin 3330 disp XP is the first high-loaded water-based dispersion of a triazine-class UV absorber. Its high stabilisation efficiency and formulation features allow improved performance at optimised costs for the most demanding water-borne coatings. Additionally, its excellent compatibility and improved VOC-related profile makes it easy to incorporate and safe to handle.

Innovation: Hempadur Impact 47800 Company Name/Developer: Hempel Features: Hempadur Impact 47800 is a new dedicated cargo-hold coating for shipowners who want a high-performance cargo-hold coating with a very attractive price/performance ratio. The coating protects ship cargo holds from both mechanical damage and severe abrasion caused while loading hard angular cargoes. With a 7.5-year major repair interval, it enables shipowners to extend dry docking periods between major cargo-hold coating repairs, thereby reducing maintenance costs. Applications: The product has been specifically developed for bulk carrier operators who want to extend cargo-hold coating repair intervals without investing in the highest performing coatings.

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NEW-AGE PAINTS AND POLISHES

Innovation: Metaflex SP 1050 Pre-treatment Company Name/Developer: AkzoNobel Features: Metaflex SP 1050 Pre-treatment—the chrome-free, water-based product—is the most recent addition to the Metaflex brand. The solution offers corrosion protection through increased adhesion of paint on metal, meeting the rigorous anti-corrosion requirements of AMS 3095. Applications: Recognised as a universal pre-treatment for commercial aircraft maintenance, Metaflex SP 1050 Pretreatment can be applied over several metals and composites. It also improves adhesion of the paint system on rivets, as compared to traditional conversion coatings and wash primer pre-treatments. A solution to simplify the aircraft maintenance process, the system brings time and cost saving benefits to the paint shop and an innovative approach in the way surface pre-treatment products are utilised in the repainting process. Reduced VOC emissions, by as much as 75%, offer an additional advantage, resulting in a non-hazardous and odourless product.

Innovation: Enza Company Name/Developer: PPG Asian Paints Features: With superior coverage and faster dry time, the solution reduces reworking as it catches less dirt. Enza offers commercial vehicles a wide range of products—primer, thinner, clear coat and solid shades. Applications: It is suitable for the commercial transport segment which comprises of taxis, autorickshaws, light commercial vehicles, dumpers, tippers and load carrier trucks.

Innovation: Nanomyte TC-5001 (Nanotechnology-enabled Coating) Company Name/Developer: NEI Corporation Features: Nanomyte TC-5001 is part of NEI’s efforts to develop corrosion-resistant coating systems, including pretreatments, primers and topcoats that protect steel, aluminium and magnesium from corrosion. The coatings are economical, easy to use and provide high levels of corrosion resistance as compared to state-of-the-art offerings. Further, the two-layer coating improves the corrosion resistance of zinc-plated and hot-dip galvanised steel. Applications: The new Nanomyte coating technology is designed to protect zinc-plated and galvanised steel surfaces from rusting under severe environmental and operating conditions.

Innovation: WB-X4789 Mercedes 047 Alubeam Silver Company Name/Developer: DuPont Refinish Features: DuPont Refinish has extended its range of Cromax special factory packed colours by introducing the Mercedes 047 Alubeam Silver—WB-X4789—with an aim to meet the growing demand for aftermarket solutions to liquid silver ‘alu-shine’ effects. The silver-mirror effect has become very popular and this trend is expected to grow. Therefore, it is important that the colour is widely available. Applications: The new water-borne base-coat colour, available in 0.5-litre tins, has been developed by including a hydroshine pigment to specifically match the Mercedes colour, Alubeam Silver.

Innovation: DuPont Teflon ETFE High Build Top Coat Powder Company Name/Developer: DuPont Chemicals & Fluoroproducts Features: DuPont Teflon ETFE High Build Top Coat Powder is a smart solution for coaters who require a high-build thickness for a part and are in need of a coating that can easily be applied up to 80 mils (2032 microns). Additionally, the new product is more chemically resistant than ECTFE. Applications: The solution was introduced for targeted applications in the chemical processing industry for parts and equipment such as vessels, columns, agitators and valves.

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ERP FOR PAINTS INDUSTRY

Stock it right! Commercially, paint is among the rather few commodities that may be classiﬁed both as an OTC product as well as an Industrial product. The selection of the paint needs to be approved by both the end client as well as the recommending authority—the contractor, architect, painter or, in some cases, the shop keeper. The industry has its special characteristics that one needs to focus on while planning & implementing an ERP. Here’s enlisting some of the factors that need to be considered while designing ERP for the paints industry… while designing an ERP for the paint manufacturing company include:

SUPPLY CHAIN RELATED ISSUES

aint is a mixture of four elements, viz., solvents, binders, pigments and additives. Solvents give the paint a liquid flow, while the binder binds it to the surface. Pigments impart colour & opacity to the paint, while additives give it special resistance properties. On product lines, paints can be differentiated into decorative or architectural paints & industrial paints. The industry is raw-material intensive. Of the 300 odd raw materials, nearly half are imported petroleum products. Thus, a deficit in global oil reserves affects the bottom line of players. Major raw materials titanium dioxide, phthalic anhydride and peutarithrithol constitute 50% of the total cost. Besides this, there are other raw materials such as castor, linseed & soybean oils and turpentine, among others. Special requirements of the paint industry that need to be factored in

Multiple units of measurement: In the paint industry, finished goods are maintained in tins. Product shades, intermediates & other raw materials are maintained in kg/ tonne, etc. The packing materials are maintained in numbers. This obviously requires the ERP to manage inventory in multiple units of measurement.

DAMAGED STOCKS MANAGEMENT Paint is usually sold in liquid form in plastic or metal drums/tins. Due to its dual characteristics of an OTC product as well as an industrial product, paints are sold in decorative & attractive packaging through a chain of hardware stores & merchants. Further, the distribution chains & networks are sometimes long. These invariably lead to damaged drums/stocks. Most often, this stock is reusable and can be reused simply by repacking it in alternate containers. For the sake of profitability, the management of the damaged stocks plays a critical role both in terms or value as well in terms or logistics. The organisation needs to manage &

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monitor the quantity and value of its damaged stock. Repacking, although possible, is rather an expensive process. The ERP system needs to track the damaged stocks at the various warehouses, locations, etc.

MULTI-LOCATIONAL WAREHOUSING & PROCESSING Again, in keeping with its basic nature of a retail industry, products need to be close to the end customer as possible. The logistics requirements of the paint industry require stocks to be maintained at various locations (warehouses, stock points, etc.). This obviously puts additional pressure on the supply chain as well as on working capital management. Further, the need to maintain the stocks as semi-finished goods adds that extra work on the ERP & supply chain planning engine. Management & control of stocks across the value chain is essential.

PRODUCTION PLANNING & CONTROL As in any manufacturing environment, the management & allocation of semi-finished goods & intermediates is extremely important. This ensures minimum in process stock/inventory. The allocation of raw materials, intermediates, semi-finished goods & packing materials to specific production batches ensures against better inventory & production batch cost control. Keeping in view the dynamics governing the process

ERP FOR PAINTS INDUSTRY

manufacturing & the uncertainties of the paint industry, production plan needs to be initiated either at the finished goods levels or the semi & finished goods levels. This is governed by the market demands & the availability of formulation in the system. Any ERP for the paint industry has to have this flexibility with respect to production planning.

CENTRAL MONITORING & CONTROL SYSTEM To ensure regional competitiveness & the inherent need in the industry to cater to regional & local demands, paint manufacturers have located manufacturing facilities at rather remote locations. In India, specific tax incentives provided to developing & backward areas have also contributed to the setting up of these plants. Although setting up plants at remote locations provides greater cost advantages, managing these remote locations poses a challenge of sorts. Often, it is difficult to get senior/ responsible managers to be stationed at these remote locations. These companies are forced to operate these plants with minimal managerial staff or staff of persons with lower managerial abilities. This inherently forces companies to develop centralised control systems that can be managed with minimum staff. As a matter of strategy, it is important to move essential activities such as accounting, HR, payroll, planning, inventory planning, administration of discount structures, production scheduling, etc., to a centralised control system. To make matters more complex, it is often experienced that communication facilities such as telephones, internet bandwidth and such communication aids are poorest at these remote locations. Hence, the ERP or management software needs to be robust to accommodate these challenges. Important transactions related to production planning, formulation definition, SKU pricing,

inventory allocation, materials planning, etc., need to have features that can be managed centrally and, at the same time, use minimum communication aids.

batch wise. The costs of finished goods and SKU are dynamically compared with the standard costs. This enables dynamic tracking of batch wise costs.

PACKING REPROCESSING, TINTING & REPACKING Another activity that is critical in the business is reprocessing & repacking of damaged or non-conforming stocks. As mentioned earlier, the management of damaged stocks plays a crucial role in the profitability of the company. Paint, in most forms, is an emulsion of solvents, pigments, binders & additives. Often, on long storage, the various elements separate. A simple act of high or medium speed stirring is essential to ensure homogeneity. It is rather uneconomical to transport tins & drums. Further, a lot of decorative paints are maintained as brite stocks at warehouses. They need to be tinted with the right pigments before being sent to the end client. That is why the reprocessing of non-conforming products, damaged products, damaged packing, etc., is an important activity in the paint industry.

REPACKING The management of packing materials damaged in transit directly adds to costs of distribution. Thus, repacking not only needs to be managed effectively, it also needs to be controlled & constantly analysed. Often, the packing material is procured from subcontractors locally. Hence, this analysis helps in identifying erring suppliers, transporters, etc.

COSTING In the paint industry, the production of all items, (intermediates, semi-finished goods, finished goods etc.), is taken up batch wise. Hence, the costs for various activities need to be consolidated batch wise. The costs of various other activitiesâ&#x20AC;&#x201D;tinting, re-processing, repacking, etc.â&#x20AC;&#x201D;are also consolidated

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The paint industryâ&#x20AC;&#x2122;s business dynamics requires the maintenance of semifinished goods in bulk form. Finished goods packing is done based on the requirement of specific pack sizes. Hence, often the sales forecasting / order booking have a direct bearing on the consumption of the packing materials.

QUALITY POLICY For effective utilisation of the various products (intermediates, semi-finished goods), the availability of quality/ analysis reports of materials in stock is essential.

BILL OF MATERIALS Keeping in view specific requirements of the paint industry, the Bill of Materials (BOM) has been designed in a multi-level structure. Further, this takes into account manufactured and bought out intermediates. BOM based on standard & specific gravity While defining the standard costs and BOM, the standard specific gravity is taken into consideration. However, while allocating materials to a specific batch, the specific gravity of the materials in stock is taken into account.

SALES The sales process in the paint industry generally consists of various forms of schemes & discounts. These schemes/ discounts may be based on quantity, value, pack sizes, products, shades and even customers. The ERP should facilitate the creation of a schemes administration system that can be managed by the company directly & does not require programmers to constantly modify the programmes. Courtesy: Octopus-e International

INDUSTRIAL APPLICATIONS

Integrating Aesthetics with Durability Paints & polishes are parts of coating that together protect the surface from degradation, oxidation, weathering damages by insects; thereby further enhancing the beauty of the material by cleaning and pigmenting its surface. With every new formulation, paints ﬁnd new and unique applications simultaneously meeting the new-age application requirements and growing standards, thus exploring and encashing on the available opportunities. SUPRITA ANUPAM

he market for electronic gadgets is increasingly growing with some of the leading companies enjoying tremendous profits even during ‘depressing’ times like the recent recessionary phase. According to market analysts, new paint technologies that offer ‘catchy’ looks— irrespective of the configuration—have contributed as one of the top 7 reasons for their business’ success. For instance, Sony Xperia S with its nano-coating, Nokia Lumia with its anti-glare and superhydrophobic coating and iPhone with fingerprint-resistant oleophobic coating, have changed the meaning of paint applications. While, they have certainly raised the bar of paint standards without dramatically changing the application, the new paint technologies explore some new applications beyond the conventional and widen their app horizon with more confidence, strength, while retaining the genX image. Paints & polishes have, so far, been majorly consumed and limited to the automotive sector, metallic & wooden applications and decorative areas. However, the future applications are poised to change with the rise of various coating technologies.

are expanding beyond the conventional areas after the rise of UV-cure coating technology. This technology has enabled the possibility of coating those areas, which earlier seemed impossible. The UV-cure coating technology has opened the gate of soft-touch coating applications— one of the latest markets of coating. The soft-touch coating imparts a silky feel owing to the polyurethane coating—resulting in stringent performance properties. The softtouch applications are not restricted to aerospace alone, but are being currently developed for use in cell phones, computer housing and automotive applications.

NANO-COATING APPLICATIONS Corrosion Reduction in Oil & Gas Transmission Pipe: Corrosion reduction has been a major concern for the oil & gas sector as many a times, it results in production stoppage and further aggravates the cost of repairing. The new nano-composite coating is now being used to prevent atmospheric corrosion and under insulation corrosion by covering almost all the micro-spaces for air penetration/percolation.

SOFT-TOUCH COATING APPLICATIONS The aerospace applications of coating

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The hydrophobic properties at the same time prevent moisture from reaching the oil and gas transfer pipeline. Though anti-corrosion coatings were already available, but insulation and anti-corrosion properties were not synchronous. Abrasion-resistant Coating Applications: The abrasion-resistant coating properties are produced by incorporating high crystallinity and extremely small particle size of alumina produced by the PVS process. Nano-crytalline alumina are evaluated by incorporating particles in a cross-linked melamine-formaldehyde resin. The coating finds its applications as protective coatings on non-flexible surfaces such as furniture and flooring. The coating uniquely suits the applications where high transparency & high abrasion resistance is required—many such applications are still under development. Of late, nano-coatings are being used in a wide number of applications, some of which include: Photonics and optical: Light filters and mirrors, SERS enhancement, potential uses for nano-coatings decorative materials, energy harvesting, wave guides.

INDUSTRIAL APPLICATIONS

Electronic: Vacuum deposition alternative, low dielectric materials, conductive/semi-conductive porous materials, non-ohmic switches, reflective /antireflective. Catalytic: Uniform micro/nano porous supports.

DIRECT-TO-METAL (DTM) APPLICATIONS UV-cure coating’s excellent adhesion to metals such as cold-rolled steel and galvanised iron have enabled the wellsuited coating for DTM applications (including large construction vehicles, trains, manufacturing equipment). So far, these were lagging in perfect coating owing to the moisture attack, uneven painting because of the difficulty at certain positions, field repairing problems, and so on.

HIGH-TEMPERATURE COATING APPLICATIONS High-temperature coating—be it at nuclear plants, coal/petroleum power plants or the optical fibres, also referred as geophysical applications—has improved with time. The silica glass in optical fibres is used to coat with hermetic coating—extremely resistant to hydrogen migration. While acrylate coatings are used for applications from 85–150°C. Tetrafluoroethylene Perfluoro Alkylvinylether copolymers are used for applications from 200-300°C.

LOW ENERGY CURING APPLICATION AREAS It was observed that traditional UVcure coatings and inks cannot be instantaneously and completely cured with the available UV LEDs, given the low energy output of the latter. The formulations still required a short distance of few millimetres between UV LED unit and the substrate. Cytec has provided ADDITOL® LED 01,which when used as co-resin, transforms UV curable formulations into lower energy, UV LED curable formulations. Commenting on the same,

AVOIDING A NECESSARY EVIL PRISM brought to India a system that fitted this bill developed by European technologists. An online paint coagulation and separation system can continuously remove the paint sludge from the circulating booth water. The system is completely automatic and very easy to operate. The system has got lot of advantages over the conventional system. Some of them are mentioned below: The change of the water in the spray booth must be carried out only every 12 months maximum. The automatically extracted sludge has a very low volume due to easy dewatering. The circulating water will be having very low percentage of paint in it at any time(Less than 0.25 %). This means booth venturies not clogged, low maintenance, consistent air velocity. By a continuous mud extraction, the booth water volume will be reduced of 70%. The concentration of the noxious substances in the air could be reduced to the better performance of the water wall. Spray booths maintenance costs will be reduced of more than 90%. It is completely automatic and the operation is very easy. How does it Work? The paint, water mixture coming from the paint booth will be mixed with the coagulation chemical in the sludge pit. A submersible pump will be provided in the sludge pit. This pump is a specially designed one and has got 2 suction points. One from the surface of the pit water and other from the pit bottom, thus it can effectively suck all the paint floating on the surface as well as the portion of sludge settling at the bottom of the pit. This pump will pump one portion of the circulating water paint mixture from the sludge pit to the flotation unit through the linear static mixture. In the linear static mixture, the water paint mixture will get mixed with the flotation chemical and as a result of this, paint sludge will start floating. Water containing the paint sludge enters the flotation unit from the bottom side; the paint sludge will float on the top surface of the water and will get removed by an automatic skimming paddle to the sludge container. The fresh water will go back to the sludge pit through a specially designed section. Courtesy: Prism Surface Coating

Stefan Smeets, Global Marketing Manager, Cytec, avers, “Cytec’s ADDITOL® LED 01 allows for more formulation freedom and opens the way to assessing UV LED curing for application areas, which were usually not accessible to UV technology, e.g., coatings on heat sensitive surfaces or field applied architectural coatings. ADDITOL® LED 01 is designed to improve the surface cure, leading to faster line speeds and allowing for a bigger distance between curing unit and substrate, necessary to cure three dimensional coated surfaces.”

FILLING THE GAP Though paint technology has improved particularly over the past few years, the gap between the application requirement & standard and the coating technology is yet to be filled. The need of the hour is better coating technology, which can sustain 1,000–3,000°C inside nuclear reactors and other thermal power plants. The multi-layered painting/coating has given some relief, but again a clear gap is yet to be filled. suprita.anupam@network18publishing.com

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INDUSTRIAL PAINTS & POLISHES

the construction, automotive and electronic appliance industries.

he Indian coatings industry has been growing at an average 15% per annum over the last decade. Growth has been consistent with the Indian GDP growth rate, and, in the last few years, the industry has grown at a rate of 1.5–2 times higher than that of the GDP growth. Construction remains the key growth sector and is driving the demand for decorative and protective coatings. The sector accounts for nearly 45% of the total national

ORGANISED VS UNORGANISED The Indian paint industry is dominated by the organised sector, which currently captures ~67% market share. The organised sector has grown at a higher rate vis-à-vis unorganised sector in last few years. The unorganised sector mostly offers lower end products like low-end enamels, distempers, lime wash, cement paint, etc. Rising disposable income and created awareness from marketing efforts by

Designing The World Beyond Imagination The Indian paint market is poised to grow at a steady rate over the next decade fuelled largely by a growing economy and changing consumer attitudes. Paint marketers have to continually meet the needs of the changing Indian consumers and regularly provide them with newer products and services to meet their requirements. Going forward, the demand scenario is forecast to remain strong backed by higher discretionary spend, increasing penetration, high construction activities and robust growth in auto & consumer durables industries. investment in infrastructure—a trend is expected to continue in the future. Growth in the Indian car market is strong, at about 10–12% per annum, which is creating good demand for OEM coatings and vehicle refinishes in the long term. The re-finish segment is enjoying growth in each of the premium, medium and economy sub-segments as a result of rising car ownership across all classes. However, as car ownership is likely to increase at the low end in the future, the greatest growth is to be expected in the economy area. Demand for coatings in India has been estimated at 22,05,000 tonne in 2011. Decorative coatings account for nearly 78% of the market in terms of volume and about 70% in value, while automotive coatings—both OEM and

refinishes—dominate the industrial segment, followed by high-performance protective coatings and powder coatings. In most developed countries, the ratio of decorative paints vis-à-vis industrial paint is around 50:50. Similarly, the per capita consumption of paints in India is very low at 800–900 gm per annum as compared to 4 kg in the South East Asian Nations and 22 kg in developed countries. The global average per capita consumption is 15 kg. Future market growth is expected to be in the order of 11% per annum overall, with individual segments displaying a broader range of growth rates across the two main segments. The demand for coatings is expected to reach 3,723,500 tonne in 2016, mainly due to impressive growth in

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organised players resulted in consumers preferring for better quality and higher end products like emulsions.

THREATS Raw material cost inflation Manufacturing of paints requires more than 300 different ingredients. Key ingredients like titanium dioxide (TiO2) and oil derivatives constitutes 15–20% and 20–40% of the of raw material cost, respectively. Cost of TiO2 is witnessing huge rise due to supply side constraints. The Indian prices of TiO2 have risen by ~29% in FY11 from 155/kg to 200/kg. The prices are continuously rising and have increased by another ~10% in two months since the beginning of FY12. Crude prices have also witnessed strong

INDUSTRIAL PAINTS & POLISHES

upsurge with improvement in global economic environment. Crude prices have risen by ~40% from US$83/barrel to US$117/barrel in FY11. To mitigate the rising cost of raw materials and to protect margins, paint companies hiked prices of their products by 8â&#x20AC;&#x201C;12%, but they were not sufficient to prevent erosion of EBIDTA margins. However, prices are expected to stay stable and partly cool off with addition of new capacities resulting better supply of key raw materials in FY13. Entry of new players: Distribution network a strong deterrent Attracted by huge market opportunities many foreign players like Sherwin Williams (USA), Nippon Paints (Japan), National Paints (Dubai) and Jotun Paints (Europe) are planning to expand in India by setting up/expanding their own manufacturing facilities or by acquiring small paint companies. Also, among top paint companies in world, some like Akzo and Kansai are already present in India and rest have either technical collaboration or a joint venture with their Indian counterparts. Threat from imports is low Despite the fall in import duty on paints from 40% to 10% in last decade, imports have not been a threat to Indian paint companies. Indian climatic conditions are not conducive for foreign formulations and modification cost in product formulation is quite high. Unorganised sector To mitigate competition from the unorganised sector, many paint companies outsource the manufacturing of low-cost products like enamels, distempers, etc. Also, the installation of DTS and offering of other value-added services like colour consultancy, home painting services and colour experience in exclusive stores strengthen the grip of the paint companies.

ANALYSING GLOBAL TRENDS The industrial coatings market is beginning to recover from the recent economic downturn. The global paint and coatings market has reached the

pre-recession level in 2010. In 2011, the global coatings market hit about $100 billion. Building decorative coatings accounted for nearly 50% of the total marketâ&#x20AC;&#x201D;the most among all coatings. Vehicle coating presents the second largest application area, making up roughly 15%, of which, OE and refinish coatings occupying about 50% and 45%, respectively. Protective and marine coating represents the third largest application field, accounting for about 12%. General industrial coating makes up roughly 10%, followed by powder coating, wood coating, etc. The paints and coatings industry majorly depends on its end-use markets. The key industrial sectors catered are construction, steel, marine and automotive. Emerging markets are showing immense potential for the growth of both architectural coatings and industrial coatings. The growing demand for green-based chemicals, such as zero Volatile Organic Compound (VOC) coatings, is driving the replacement of solvent-based products with water-based products. The industrial coatings segment also has significant share in the market and paint makers are focussing on cuttingedge technological innovation to satisfy both consumers and regulatory demands. The industry is dealing with several issues, the major being the unprecedented escalation in the price of oil, natural gas and raw materials, which is having a significant impact on the marine coating industry. Growth in the global market would be spurred by the increasing stringency in regulations, rising competition, growth in unique formulations and technological and product developments. However, the industry seems to have turned its fortunes around with demand being encouraged by several new styles of automobile coatings that incorporate nanotechnology. Water-based coatings are the future of the US automotive coatings manufacturing market and are expected to boost demand for coating customisation, given their ease of use

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and lower potential cost once the technology is widely adopted. Revenue within the US automotive coatings manufacturing market has been forecast to grow at a CAGR of 2.7% over the next five years, to reach a total market value of $1.5 billion in 2017.

PROMISING OUTLOOK According to an upcoming study by consulting firm Kusumgar, Nerlfi, & Growney, the global consumption of coatings in 2012 is projected to come in at 67 billion pounds, worth $120 billion. While the volume has bounced back from 2009, with the Asia-Pacific region leading the way; growth in 2012 slowed down owing to global & local economic uncertainties. Coating volume in 2012 is up 15% since the 2009 global recession, but coating value is up by about 1/3rd, mainly because of escalation in raw material prices. The Asia-Pacific region is the largest consumer of coatings, taking 42% of the volume in 2012. Europe is the second-largest market for coatings, taking 27% of the global volume in 2012. Consumption in 2012 was hurt by the regionâ&#x20AC;&#x2122;s economic crisis. North America was an outlet for 1/5th of the global coating volume and has mature growth prospects. South and Central America region accounted for 8% of the global demand in 2012. Growth in the region slowed in 2012, but is forecast to grow modestly in the future. Going forward, the Indian paint industry is in the sweet spot. Rising income and aspiration levels of young demography along with changing lifestyle has catapulted the demand for both repainting and fresh paints. Currently estimated at ~`210 bn, the Indian paint industry has grown at a CAGR of ~18.5% in last two years and expected to grow at a CAGR of ~17.5% in next four years to become a `396-bn industry in FY15. Compiled by Deepa Sharma With inputs from research report by SPA Securities Ltd.

OIL, COOLANTS & LUBRICANTS I

In the News

Universal Lubricant evinces interest in developing Azhikkal Port The Sharjah-based Universal Lubricant Group has evinced interest in the development of Azhikkal Port in Kannur, Kerala. The company has earmarked `150 crore towards developing the port into a modern facility. ExxonMobil to expand 2 La. chemical plants ExxonMobil is expanding its Louisiana chemical and lubricant plants, which will generate over 400 construction and full-time jobs in the state over the next two years. Construction on the $200 million chemical and lubricants plants in Baton Rouge and Port Allen will begin at the end of the year. The project will make Baton Rouge plant the world’s largest producer of finished lubricants used in motor oils, gear oils and greases. The expanded 8.3-acre plant will replace an existing manufacturing facility in New Jersey, the US. Pertamina enters lubricant market in Japan PT Pertamina is working with Japanese automotive giant Toyota to expand the state energy firm’s lubricant business in Japan. Ultimate Linings produce protective chemical coatings for oil & gas industry Ultimate Linings (UL), a leader in the development and application of protective coatings & linings, has announced the growth of its industrial scope of work to include the Eagle Ford Shale and Marcellus Shale. UL shows growth, within the oil & gas industry in the US, through their innovative protective chemical offerings and mechanical engineering skills. GlyEco Completes Asset Purchase Agreement with Antifreeze Recycling Inc. Cleantech innovator GlyEco, Inc. has announced an asset purchase agreement to acquire Antifreeze Recycling, Inc. located in Tea, South Dakota, the US. The two parties entered into a preliminary agreement in June, 2012. This transaction supercedes any prior agreements and is scheduled to close on October 26, 2012. The company expects the closed transaction to be immediately accretive.

Demand for premium lubricant products is growing: The migration towards advanced premium lubricants is being driven by environmental concerns and automakers seeking premium, precisely formulated lubricants that can be used globally on advanced engine technologies and hardware. For example, CAFE regulations call for light-duty vehicles to achieve 54.4 MPG by 2025. Lubricants will play a major role in getting there. Top shops are adopting a proactive mindset: They are implementing new procedures that optimise maintenance procedures, change intervals, training and documentation to bring added value to their customers and grow trust, relationships and loyalty. Predictive maintenance lubricant programmes are supplanting reactive and even preventive maintenance programmes: These programmes incorporate onsite oil analysis, investing in modern sampling hardware and rigorous training of maintenance staff. Similar to personal healthcare, it is akin to discovering indicators of potential problems early, before they become chronic or catastrophic. Optimised oil changes are trending to being condition-based: No one interval fits all. Condition-based maintenance balances taking all steps reasonable to prolong the oil’s service life with changing oil when its remaining useful life is nearly spent. Knowledge and preparation are enablers: Keeping informed about changing vehicle demands, as well as the new and emerging lubricants that are being developed and introduced are becoming competency differentiators between shops. High-quality filtration is required to keep pace with advances in vehicle and lubricant technology: Better-quality filtration, including aftermarket secondary loop products, can provide cost-efficient reduction of removing dirt from oil, enhance capture efficiency and prolong lubricant life. A ‘lube-savvy’ workforce does more than treat the symptom: They also ask why, and then uncover the underlying root causes. They know when, where and how to perform their craft.

Compiled by Prateek Sur

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Emerging Trends

OIL, COOLANTS & LUBRICANTS

OIL SELECTION PARAMETERS: How Healthy Is Your Oil? ...........................................................82 DIESEL FUEL LUBRICITY: Boon Or Bane?.......................................................................................85 REFINING OIL: Depreciating The Lubricating Value? ......................................................................88 MOTOR OIL SELECTION GUIDE: How Well Do You Know Your Motor Oil? .............................92 ANTIFREEZE COOLANTS: Corrosion Inhibitors @ Work ............................................................94 3D MODELING AND RAPID PROTOTYPING OF A CRYOGENIC LIQUEFIER: Coolant Enhancement Via Liquefaction ...........................................................................................96 NEW AGE MAINTENANCE TECHNOLOGIES: How Painful Is Flushing The Coolant Out? ...........................................................................................................................104

Photo By: Prateek Sur

VACUUM DISTILLATION TECHNOLOGY: Recycling Gets Tech Advantage ...............................106

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OIL SELECTION PARAMETERS

How HEALTHY is your

OIL?? OIL

Selecting lubricating oil is one of the primary criteria that any company should consider before starting any process in their facility. Unfortunately, this is not the case. Companies scarcely pay heed to the oil that is selected and just go by word of mouth. However, selection of the oil should be of utmost importance to any process inside the facility. Let’s look at some of the criteria under which a company should test and check whether the oil they are selecting is actually healthy enough. PRATEEK SUR

ELEMENTAL ANALYSIS Elemental analysis reports about the concentration of 21 different elements present in the oil. This is done via Inductively Coupled Plasma (ICP) spectroscopy, which detects elemental wear in metals & additives that are sized 10 micron and smaller.

OIL CONDITION ANALYSIS Oil condition reflects the ability of any oil to lubricate and preserve the machine parts just as it was designed. Degradation of any oil may be seen from the changes in the additive elements. It is generally assessed by the following measures: Oxidation: In case of iron, oil oxidises when oxygen amalgamates with the oil molecule. Oxidation is accelerated by high temperature, contaminants and constant agitation. The most perceptible change is thickening of oil. Soot: Soot is the insoluble residue of partially burned fuel. It is held in suspension by oil additives, which turns engine oil black. The soot particles are abrasive and cause engine wear. They are usually a function of the combustion system air/fuel ratio. Sulphation: Sulphur is present in diesel fuel. During combustion, this fuel sulphur combines with water to form sulphuric acid. Modern diesel engine lubricants are designed to neutralise this acid. However, if these acids reach unacceptable levels, the lubricant will degrade and the engine piston walls will begin to corrode. Nitration: Although nitration occurs in all engines, it is a major consideration only in natural gas engines. Viscosity: This is the most important property in selecting the correct oil for an application. It is a measure of the oil’s ability to flow at a given temperature. Viscosity is affected by oxidation and contamination of oil. Visual Inspection: Darkening of oils may be an indication of oxidation, or soot in engine oils.

OTHER OIL CONTAMINANTS Contaminants result from outside sources or from chemical changes in the oil. Contaminants such as fuel, water, ethylene glycol and soot originate from outside sources. Oxidation, sulphation and nitration are due to chemical changes in the oil. The contamination caused by various oil contaminants can be measured under the following categories: Particle Count: Particles in the oil are optically measured using light obstruction sensors and a photodiode detector. Consider the result as X/Y. The ‘X’ factor represents the number of particles larger than 6 microns, while the ‘Y’ factor represents the number of particles larger than 14 microns. The ‘X’ and ‘Y’ are reported as per the ISO code system of 28 numbers, each representing a given range of particles per ml of oil. Water: Water may condense or leak into a compartment, or can also enter as a result of pressure washing equipment. It can cause corrosive wear and rusting in any compartment. Water may also form sludge in oils, increasing viscosity. Fuel: Fuel dilution in oils will decrease viscosity and affect oils’ lubricating and protecting qualities. Fuel dilution will be evident through a drop in viscosity, but is also validated by a secondary fuel test. Glycol (coolant): Contamination from ethylene glycol causes oil to thicken. The sludge formed in the process may cause further added complications. Further, ethylene glycol acts as a catalyst, speeding up oxidation. Depending upon the brand and type, coolant in oil may be detected via levels of sodium and potassium, apart from other select elements for specific coolant brands. prateek.sur@network18publishing.com

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SEARCH November 2012 Ad Name: C&S Pg No. 83

SEARCH November 2012 Ad Name: Rotomotive Pg No. 84

DIESEL FUEL LUBRICITY

PRATEEK SUR

ost diesel fuel injection apparatus more or less depend on diesel fuel as a prime lubricant. The lubricating characteristics of diesel fuel are vital, particularly for rotary and distributor type fuel injection pumps. In these apparatus, the moving parts are oil lubricated by the fuel itself—a process that is done simultaneously as the parts move through the pump (with the engine oil not playing any role here). A majority of the diesel fuel systems including injectors, unit injectors, unit pumps and in-line pumps are fractionally fuel lubricated. In these systems, the mechanism characteristically consists of a plunger or needle operating in a sleeve or bore, where the fuel is used to lubricate the walls between the counter reciprocating piece and its container. The lubricity of fuel is a sign and measure of the amount of wear or scarring that takes place between two metal parts enclosed with the fuel as they come into contact with each other. Low lubricity fuel causes high wear and scarring, while high lubricity fuel provides reduced wear and longer component life.

Boon or Bane? Lubricity, the measure of the reduction in friction of a lubricant, cannot be directly measured, so tests are performed to quantify a lubricant’s performance. By determining how much wear is caused to a surface by a given friction-inducing object in a given amount of time, lubricity can be measured. Other factors such as surface size, temperature, and pressure are also speciﬁed. The greater the wear or scar, the worse the lubricity. For this reason, lubricity is also termed a substance’s anti-wear property. The study of lubrication and mechanism wear, called tribology, has helped ﬁnd that the biodiesel added in any normal diesel oil can better the lubricity of any fuel. Here’s how...

LUBRICITY V/S VISCOSITY Lubricity has sometimes been compared to the viscosity or thickness of a fuel. However, according to a statement by Lucas, the leading fuel injection equipment manufacturer in England that was recently purchased by Delphi, “Lubrication of fuel is not directly provided by the fuel’s viscosity, but by other components in the fuel which prevent wear on contacting metal surfaces.” For years, the lubricity of diesel fuel was considered sufficient to provide the required protection to maintain adequate performance. The latest modifications in the composition of diesel fuel have unintentionally resulted in the removal of some compounds that provide lubricity to the fuel. However, it is important to note here that while some modifications were done because of the need to reduce fuel sulphur & aromatic levels, others occurred owing to the common chemical process called hydro-treating. Elaborating further on the lubricity issues faced by many, Paul Henderson, Quality Management Systems Manager, Stanadyne Automotive Corp, explains, “There have been numerous examples from the field where lack of lubricity in the fuel has caused premature equipment breakdowns and, in some cases, catastrophic failures. This problem will be more dramatic as environmental agencies move to further reduce the sulphur levels in petro-diesel fuel.” Additionally, the lubricity of diesel fuel can fluctuate noticeably and is reliant on a wide range of aspects, including: The crude oil source from which the fuel was formed The refining processes used to produce the fuel How the fuel has been handled throughout the distribution chain The inclusion of lubricity enhancing additives, i.e., whether alone or in a package with other performance enhancing additives. All these add to the lubricity of the diesel fuel. Ideally, kerosene, as a diesel fuel, is used in colder climates and has poorer lubricity in comparison to other diesel fuels. According to a review recently conducted on fuel lubricity

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DIESEL FUEL LUBRICITY

LUBRICITY BENEFITS OF BIODIESEL Adding biodiesel, even in little measure, has shown to increase fuel lubricity using a variety of benchscale test methods. The two most accepted bench test methods for lubricity are the Ball on Cylinder Lubricity Evaluator (BOCLE), and the High Frequency Reciprocating Rig (HFRR). BOCLE is usually used to assess the lubricity of fuels or fuel blends, but does a poor job of distinguishing the lubricity of fuels including lubricity additives. HFRR, on the other hand, is commonly used for both neat fuels and fuels containing small amounts of lubricity enhancing additives. Fuel Injection Equipment (FIE) manufacturers use HFRR, and advise that all diesel fuel meet a limit of 460 micron maximum Wear Scar Diameter (WSD). For HFRR, a lower wear scar indicates better lubricity. Biodiesel has been tested, at varying concentrations, with poor lubricity diesel fuels. This is indicative of the fact that fuel is refined to meet 500 ppm

maximum sulphur New age technologies have certainly content. With respect reduced the risk of oil spills—a long-standing to other fuels, while 1% problem associated with oil production. biodiesel was enough While these new technologies assist human to attain the desired operators to make informed decisions, any increase in lubricity, diesel error on the part of the operator can cause fuel took almost 2%. In a disaster. addition, most of the lubricity benefits of the biodiesel were achieved by adding only looking to protect the environment, 2% biodiesel to the normal fuel. have come up with a solution. To this, Henderson adds, “We have By working with designers of oil tested biodiesel at Stanadyne and the filters, they have developed filters results indicate that the inclusion of that trap the particles more effectively 2% biodiesel into any conventional than traditional oil filters. As a diesel fuel will be sufficient to address result, the old oil becomes ‘cleaner’. the lubricity concerns that we have This, in turn, causes less pollution to with the existing diesel fuels.” the environment and minimises “From our standpoint, the inclusion the damaging affects of disposal of biodiesel is desirable for two reasons. in landfill sites. While this is just First, it would eliminate the inherent one method oil companies are variability associated with the use of using, their scientists are constantly other additives. Second, we consider researching ways and means to devise biodiesel a fuel or fuel component environment-friendly techniques to and not an additive. Thus, to dispose of used oils. increase lubricity, if more biodiesel is added than required, then there WORKING TOWARDS A SUSTAINABLE will not be any adverse consequences FUTURE that might be seen if other lubricity According to Henderson, “Biodiesel additives are dosed at too high a rate,” fuels consisting of methyl esters of Henderson explains. soybean oil had excellent scuffing The support of 2% biodiesel and adhesive wear resistance that makes biodiesel an ideal solution to exceed those of the best conventional the existing lubricity problem with diesel fuels.” diesel fuel, while supporting other In a modern diesel engine, the environmental, energy security and fuel is part of the engine lubrication economic development initiatives. process. Diesel fuel naturally contains As environmental agencies force sulphur compounds that provide good further removal of sulphur from diesel lubricity, but because of regulations in fuel—which will certainly deteriorate many countries (such as the US and fuel lubricity—the concentration of the EU) sulphur must be removed. biodiesel can be raised to the required Reformulated diesel fuel that does levels to fully protect future fuel not have biodiesel added has a as well. All such test results show a lower lubricity and requires lubricity significant improvement in lubricity improving additives to prevent when adding biodiesel to all fuels. In excessive engine wear. Thus, the rest fact, biodiesel tested higher in lubricity of the nations should take cue from the than any other diesel fuel tested ever. US and the EU and adopt biodiesel as a fuel. This would definitely help us save fuel and sustain it for future REDUCTION IN LOCAL ENVIRONMENTAL generations. POLLUTION Disposal of engine oil has always been a problem and oil companies, prateek.sur@network18publishing.com

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FAC T FACT

worldwide, diesel fuel in the US and Canada was one of the poorest lubricity fuels found in the entire world. Of the 27 countries surveyed, Canada, Switzerland, Poland and Taiwan had poorer lubricity fuel in comparison to the US. The US data contains information pertaining to diesel fuel refined to meet the present day environmental agencies restriction of 500 ppm maximum sulphur specification. This should be a wake up call for the rest of the nations who have less or no idea about fuel lubricity. Moreover, the severe hyrdrotreating required to reduce fuel sulphur to the new environmental agencies specification of 15 ppm sulphur maximum causes further reduction in fuel lubricity as compared to the present diesel fuel. It is therefore a cause of worry for engine and fuel injection equipment manufacturers.

REFINING OIL

Depreciating the

Lubricating Value? Of the numerous commodities used in our day-to-day lives, perhaps, there would not be anything that the common man would be more aloof about than our common lubricating oil. Consumers know little about it, although such great amounts are used by them everyday. The interest in this liquid, greasy substance is more striking when we know that our daily lives highly depend on it. PRATEEK SUR

ubricating oil, one of the numerous products extracted from petroleum, is processed by placing the crude petroleum in large stills and slowly heating it. The gradual rise in temperature results in the formation of many byproducts of petroleum, which are in vapour form. These vapours are then passed onto the condensing chambers, where they are gathered as liquids—called ‘distillates’. Meanwhile, the less volatile part of petroleum remains in the stills as residues and consists of very thick, viscous lubricating oil, called ‘residuum’. Diverse techniques are used in the preparation of ‘distillates’

and ‘residuum’ for the market. In most cases, ‘distillates’ and ‘residuum’ are sold to the trade, while the remaining byproducts of petroleum are used in the same form as they come out from the stills. The ones sold to the trade have had either a chemical or filtering treatment, or both. The most common practice is to subject them to a treatment with strong sulphuric acid, which has the outcome of altering some of the constituents of oil. This, in turn, helps demarcate the useable oil from the sludge, which gets formed during the process. This sludge is then removed from the oil and the oil is then treated with caustic soda for removing the remaining constituents of the original oil, thereby neutralising the acid, if any, in it. Lastly, to remove all traces of caustic soda, the oil is washed with water, after which the finished product is achieved. While these processes are aimed at bettering

the quality of oil, the question that arises here is ‘if lubricity is such a crucial factor, then why is there a need to refine the lubricant even further?’ According to WB Hardy, Physicist, UCLA, “The function of lubricants is to keep the applied surfaces in a neutral condition by maintaining a ‘grease’ film on each. One broad conclusion emerges from these facts; namely, that lubrication depends wholly upon the chemical constitution of the fluid, and the fact that the true lubricant is able to render slipping easy when a film of only about one molecule deep is present on the solid surfaces, suggests that the true lubricant is always a fluid which is absorbed by the solid face. If this be so, then the problem of lubrication is merely a special problem of colloidal physics.” Hardy, also a Fellow of the Royal Society, explains that the presence of colloids increases the efficiency of lubrication.

DIMINISHING THE OIL’S LUBRICATING VALUE Most of the lubricating oils are treated with a chemical treatment called filtration. When practiced on ‘distillates’, filtration seems baseless as there should be no solid matter in these oils. Moreover, these oils are presentable. Nonetheless, this expensive preparation for the market has unavoidably augmented the cost of the original ‘distillates’ and ‘residuum’ significantly. Nowadays, consumers are more aware and are keen to know if the oil they buy is improved in terms

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REFINING OIL

of lubricating value, or is merely given a face-lift and made more saleable at the cost of its efficiency? After all, the cost of a little amount of lubricating oil enters into the cost of the flour we eat, the clothes we wear, the articles we purchase and so on. Elaborating further, Edward G Acheson, ScD, former President, American Electrochemical Society, opines, “When we say lubricating oil, we are using the singular to designate many, for various oils are offered and sold on the market under as many names as there are oils, the sole difference in most cases between them being their thickness or body, termed as ‘viscosity’. It is the physical difference between the thin, limpid sugar water as it runs from the maple tree, and the thick maple syrup produced by boiling down the water.” But this comparison of viscosity has no suggestion to a lubricant. Acheson explains, “In the process of distilling of the various parts of crude petroleum, lubricating oil is, in practice, separated into a number of oils of different viscosities and all of them find their places in the industrial world. Low viscosity oil is used when light work and high speed are required, while high viscosity oil is used when there is a requirement for heavy work and slow speed. The viscosity of any oil used in a bearing carrying a certain load or strain should be such that it would prevent the film of oil from breaking; thereby permitting the shaft and bearing materials from coming into contact.” “Viscosity’s sole purpose is to prevent, or at least reduce, the liability of the breaking of the oil film between rubbing metals, or, in other words, it has much to do with keeping the metals separated,” adds Acheson. However, this is not adequate for competent lubrication. Any body that keeps the metals apart should have ‘greasiness’ to be a good lubricant. Lubricating oils extracted from petroleum are greasy to a very high extent. It is remarkable

Example of an oil company using its own product in carrying out lubrication contracts A very large percentage of the US railroads’ rolling stock is lubricated by a subsidiary company of one the largest petroleum refining companies. It is understood that this lubrication is done on the basis of car mileage and, evidently, it is in the interests of the oil company to secure the maximum lubrication with a given amount of oil. (They are selling lubrication, not oil.) To arrive at some idea of the conditions to be met in this case of lubrication, two railroad cars were selected at random and an examination made. Each car had stenciled on its sides its respective weight and capacity. One was a steel hopper car weighed 37,200 pounds and had a capacity of 110,000 pounds. Hence, when loaded, it would weigh 147,200 pounds. The car was carried on eight bearings, each measuring 4x10 inches, giving 320 square inches as the total bearing surface supporting the load. Each square inch of the bearing surface carried 460 pounds. The second car examined was a box-car with a total weight, when loaded, of 98,800 pounds, but its bearing surfaces measured only 208 square inches, which gives us 470 pounds to the square inch. The bearings of these cars were expected to carry well-nigh twice the load or strain carried by the average of the bearings in our manufacturing plants, and it is fair to assume these are typical examples of the millions of bearings that are being lubricated by this subsidiary of an oil-refining company. For this railroad-car lubrication do they use refined oils or distillates? On investigation, it was found that they used distillates. that a liquid, whose value lies in its lubricating qualities, is subjected to a treatment that would diminish those qualities to a bare minimum. Yet, this is the practice! But why do refiners subject oil to this treatment? Do companies use the oil that has been treated in this manner for their personal use? This reasoning has to be left open-ended. Some people may be adequately invidious to recommend that this process was done for the purpose of reducing the oil’s lubricating value, thereby curbing the life of the oil, which, in turn, would call for more frequent buying.

THE REASONS In order to trace the real reason for this costly, complex treatment, the early days of oil refining have to be studied. The initial endeavours were to produce a fine, clear oil and the processes of refining were developed along those lines, resulting in the establishment of certain standards that are being followed till today. In that era, there was, in fact, no reason for giving thought to saving oil. No deliberation was given to the fact that

the treatment it was receiving was robbing it of a certain percentage of its true worth. The conditions today have changed considerably. The present call is to conserve and thereby attain the maximum value at a minimal cost. In order to get the desired conservation at a low cost, companies run up against the standards created in those early days. Acheson, seconding the thought, explains, “They play a large part in the competition between rival oil interests. The oil salesman displays his wares before a prospective customer who may be the purchasing agent of a large manufacturing company. The clearness and brightness of the oil is expatiated upon. Its entire freedom from carbon is commented on. Its very viscosity is dwelt upon. But are the lubricating qualities discussed? You might get a probable ‘NO’ as a reply.”

WHAT REFINING COSTS THE PUBLIC? How much is the public paying for this refining? Citing an example, Acheson explains, “I know of one instance where heavy, filtered lubricating oil was selling at 38 cents a gallon, while that of unfiltered oil was 16 cents

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REFINING OIL

Brief description of some of the most important friction element Elemental Analysis

Copper (Cu) Iron (Fe) Chromium (Cr) Lead (Pb) Aluminium (Al) Tin (Sn)

Reported in ppm (parts per million), the presence of each element will fluctuate according to hours/miles in use, oil added, recent repairs and other factors Bearings, bushings, thrust washers and brass parts. Engine readings may vary dramatically. Rust, gears, shafts, cylinders, valve train components and liners in some applications. Piston rings, chrome plated crankshafts, some exhaust valves, roller and ball bearings. Found in many bearings, rod, turbo, camshaft and some bushings. Gasoline additive. Bearings, thrust washers, converter, pump bushings and pistons. Dirt entry from clay soils. Piston plate coating. Overlay of connection rod and crankshaft main bearings. Wear indicator in some bearings, shafts or valves. Wear of some bearings, secondary indicator for cooler.

Nickel (Ni) Silver (Ag) Other Contaminants: Titanium (Ti) Alloy in high quality gears and bearings Sodium (Na) Inhibitor from cooling system or oil additive. Environmental contaminates (salt water). Silicon (Si) Caused by dirt or dust entry

per gallon. The refiner was asked to substitute the unfiltered oil for the filtered oil. If this reduction was solely due to cutting out filtration, we must assume that the filtering of this oil cost 22 cents per gallon. But this was an extreme case as the oil was very viscous.” Acheson elaborates further, “To be conservative and within the bounds of possibility, let us take two cents as the cost of refining one gallon of lubricating oil as the average for all oils. There are 50 gallons to a barrel. Consequently, it would cost $1 to refine one barrel of oil. In 1918, there were approximately 34,000,000 barrels of lubricating oil produced in the US. If the consumers were paying $1 for refining one barrel of oil, it paid $34,000,000, or at the rate of $1 per barrel for the portion that had been refined. This amount could instead be used to market the oil.”

IMMENSE LOSS OF POWER BY FRICTION According to oil manufacturers, consumers have become more literate now and demand brighter coloured oil. Even if this is partially true, then who educated them to differentiate? Did

any company head look into it to see whether the oil they are paying great sums of money for, is clear and bright in colour, or did he simply investigate as to whether or not it is efficiently lubricating? Has any purchasing agent ever received evidence that the bright, clear oil sold to him by an oil salesman was even equal to a cheap, dark oil of equal viscosity? It is a well-known fact that one-half of the mechanical power used in the manufacturing plants is lost in friction, which means that onehalf of the coal consumed to make steam and develop power is lost due to friction. It is evident that the manufacturer or purchasing agent is dealing with a critical question when selecting the oil that lubricates best so that this loss may be reduced. The oil takes a short step from the container—in which it is delivered to the manufacturer—to the bearing in which it is used. During this passage, no one pays any attention to its colour or clearness (water white, amber or red oil, or any other brightcoloured oil) available in the market. It would only be a matter of a few minutes for the oil to turn black after it has been placed in the bearing.

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However, it is important to note here that colour has nothing to do with the lubricating value of oil. However, at a time when the nation is up on its heels to conserve our essential resources, especially when the cost of living is affected, is it not significant to draw attention to this uncalled for waste (in terms of money and in terms of waste of a valuable natural resource)?

REFINED FUTURE Companies must draw the conclusion that it is only when they sell oils to consumers for the purpose of lubrication that they use the refined product. But when their own interests are at stake, especially when the work to be performed is of the most severe nature, they use distillates. Presumably, those dealing with oil are experts in matters pertaining to lubrication. They are aware of the conditions under which the oil is best suited to produce maximum lubrication. With the knowledge that they use distillates only when their own earnings are at stake, and sell refined oil with a decreased lubricating value to other users, will naturally lead one to think that they are not playing fair to consumers. They will naturally assume that one of the most valuable natural resources is being used for the personal advantage of companies and individuals, at the cost of the consumers. Under the current laws, it is not permitted for an entity or any firm to manufacture drugs or foodstuff without conforming to rules that have been carefully drawn by the government. This is done so that the buying public may have the highest and best return for its money. Is it not time that the government itself takes action to ensure that our remaining stock of petroleum is used to the very best advantage of everyone, and not only a select few? prateek.sur@network18publishing.com

MOTOR OIL SELECTION GUIDE

How well

do you

Know your

Motor Oil? Selecting the best motor oil is an issue that resurfaces habitually in discussions among moto-heads related to motorcycles, cars, trucks and heavy rollers, among others. The advertising hype surrounding motor oils makes it even more difﬁcult for a layman to measure the parameters of selecting the appropriate one. Here’s an attempt at trying to help consumers select the right motor oil... PRATEEK SUR

il companies make available the data about their oils for the benefit of the common man. Most companies refer to this as ‘typical inspection data’. This data is only a gist of the real physical and some common chemical properties of their oils. This information is made available to the public through oil

distributors. At times, a buyer can also get this information by directly writing or calling the company. The data can be assessed after looking at six of the most important properties of any motor oil, namely viscosity, Viscosity Index (VI), flash point, pour point, percentage of sulphated ash and the percentage of zinc.

VISCOSITY Viscosity is a measure of the ‘flow ability’ of any oil. More exclusively, it

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is the property of an oil to develop and maintain a certain amount of sheering stress dependent on flow and then to offer continued resistance to flow. Thicker oils generally have a higher viscosity, while thinner oils have a lower viscosity. This is the most important property for an engine. Oil with too low a viscosity can shear and loose film strength at high temperatures. Oil with too high a viscosity may not pump to the proper parts at low temperatures and the film may tear at high rpm. The weights that are written along with the oils are arbitrary numbers assigned by the Society of Automotive Engineers (SAE). These measurements are taken at specific temperatures. Oils that fall into a certain range are designated 5, 10, 20, 30, 40 and 50 by the SAE. ‘W’ means that the oil meets specifications for viscosity at various low temperatures depending on weight, and is, therefore, suitable for ‘winter’ use. In multi-viscosity oils, polymers are added to a light base, which prevent the oil from thinning as much as it warms up. At cold temperatures, the polymers are coiled up, allowing the oil to flow. As the oil warms up, the polymers begin to unwind into long chains that prevent it from thinning as much as it normally would. As a result, at 100°C, the oil will be thinned only as much as the higher viscosity number indicates. Multi-viscosity oils are one of the great improvements in oils; but, they should be chosen wisely. It is always advisable to use a multi-grade oil with the narrowest span of viscosity that is appropriate for the temperatures, which might be encountered. The choice should depend on the lowest temperature encountered in winter and the highest temperature encountered in summer. The polymers can shear and burn forming deposits that can cause ring sticking and other problems. This has created problems in diesel engines before; however, it is always advisable to use fewer polymers for engines.

GETTING INFO ABOUT OIL

The wide-viscosity range oils are more prone to viscosity and thermal breakdown due to the high polymer content. One important thing that should be kept in mind, as told by an industry expert, “It is the oil that lubricates, not the additives. Oils that can do their job with the fewest additives are the best.”

VISCOSITY INDEX VI is an empirical number that indicates the rate of change in the viscosity of an oil within a given temperature range. Higher VI indicates a low change whereas lower VI indicates a relatively large change. The higher the VI the better it is. This property of oil keeps the bearings smooth. The industry expert further adds, “The VI numbers can only be compared within a specific viscosity range. It is not an indication of how well the oil resists thermal breakdown. So that should also be kept in mind.”

FLASH POINT Flash point is the temperature at which oil gives off vapours that can be ignited with a flame held over the oil. The lower the flash point the greater is the tendency of the oil to suffer vaporisation loss at higher temperatures and to burn off on hot cylinder walls & pistons. “The higher the flash point, the better it is. The minimum temperature to prevent possible high consumption is 400°F,” avers the industry expert.

MYTHS DE-MYSTIFIED The ‘better’ oils always remain the ‘better’ oils. The formulation of oils is continually being updated and is subject to change by the manufacturer at any time. The best option is to gather data on the oils directly from the oil company. Synthetic oils offer only truly important disparities due to their better high temperature oxidation resistance, high film strength, very low tendency to form deposits, stable viscosity base and low temperature flow characteristics. Synthetic oils are better-quality lubricants compared to traditional petroleum oils. The user has to decide if the high cost is justified for their application. The extended oil drain intervals given by the vehicle manufacturers (usually 7,500 mile) and synthetic oil companies (up to 25,000 mile) are for ‘normal service’. Normal service is defined as the engine at normal operating temperature, at highway speeds and in a dust-free environment. Stop and go, city driving, trips of less than 10 mile, or extreme heat or cold puts the oil change interval into the severe service category, which is 3,000 mile for most vehicles. Synthetic oils can run 2-3 times the mileage of petroleum oils without any problems. They do not react to combustion and combustion byproducts. The longer drain intervals possibly help in taking the bite out of the higher cost of the synthetic oils. If a car or bike is still under warranty, it is recommended to stick to the drain intervals. If the oils are used in compliance with the company’s recommendations (including extended drain intervals) and a problem is caused by the engine oil, the company will pay for the repairs. Users should check with the company for specifics of any warranties offered. Oil additives should not be used. Oil companies have gone to great lengths to develop an additive package that meets the vehicle’s requirements. Some of these additives are synergistic, i.e., the effect of two additives together is greater than the effect of each acting separately. If the user adds anything to the oil, it may upset the balance and prevent the oil from performing to specification. Numbers are not all that determine what top quality oils should have. The exact base stock used, the type, quality and quantity of additives used is very significant. The given data with the oils along with the manufacturer’s claims, the user’s personal experience and the reputation of the oil, among others, who have used it, should help the user take an informed decision. manufacturers. The lower the pour point, the better it is.”

PERCENTAGE OF ZINC

anti-wear additive. The zinc is only used when there is actual metal-tometal contact in the engine. Generally, the oil does its job perfectly and such zinc-related problems rarely occur. If it happens, the zinc compounds react with the metal to prevent scuffing and wear. A level of 0.11% is enough to protect an automobile engine from the extended oil drain interval, under normal use. “More doesn’t give you better protection; it gives you longer protection if the rate of metal-to-metal contact is abnormally high,” concludes the industry expert.

The percentage of zinc is the amount of zinc that is used as an extreme-pressure,

prateek.sur@network18publishing.com

PERCENTAGE OF SULPHATED ASH POUR POINT Pour point is 5°F above the point at which chilled oil shows no movement at the surface for five seconds when inclined. This measurement is especially important for oils that are used in winter. A borderline pumping temperature is given by some manufacturers. The industry expert seconds this by saying, “This is the temperature at which the oil pumps and maintains adequate oil pressure. This is generally not given by many

The percentage of sulphated ash is the measure of how much solid material is left when oil is reacted with sulphuric acid and burned. This is used to quantify the amount of metallic antiwear and detergent additives in the oil. Zinc dithiophosphate is a common detergent and anti-wear additive that is reflected in this test.

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ANTIFREEZE COOLANTS

@ WORK

Corrosion inhibitors

Concerns over the effects of new types of antifreeze on older engines have been raised time and again. What goes wrong if coolant service and maintenance recommendations are not followed? The debris from corrosion accumulates, it then agglomerates to form large hard particles which with scale deposits from hard raw water will damage the water pump seal and cause leakage. Let’s look at some ways in which antifreeze coolants can help users get a better deal.

PRATEEK SUR

ntifreeze (A/F) has a prewar origin; it was first marketed commercially in 1937. It became very popular, but also carried with it the risk of internal corrosion, which prompted the development of inhibitors to protect the water side of an engine from attack. Anti-foaming additives & scale-reducing chemicals followed and created a product that is now being universally used. Coolant is the mixture of A/F and water present in the radiator, engine and cabin heater. It is designed to be used all year round. A coolant is circulated round an engine by a water pump to control temperatures in critical components (like the cylinder bore, piston, rings and cylinder head, particularly around the exhaust valve and spark plug) that become very hot. Hence, it is important that the correct physical and chemical properties are maintained for the coolant to fulfill its heat transfer and corrosion inhibiting functions at extremes of low and high ambient temperatures.

HOW MUCH HEAT? The combustion of a petrol and air mixture creates horsepower at the flywheel along with exhaust gas and heat that is engrossed by the coolant— all in just about equal amounts. While

it is important to have a robust cooling system, it is equally important to have a clear airflow to the radiator as a badly positioned number plate, badge bar, auxiliary lights and even a large rally plaque can all contribute to restricted air flow. Overheating follows and even with a sound pressure cap coolant is rapidly dumped.

the cylinder head. Similarly, the coolant transfer ports behind the front cover and between the cylinder head. The intake manifold are sealed with robust gaskets, leakage rarely occurs and there is no corrosion at bolted joints or inside the water jacket if the recommended coolant practice is followed.”

ANTIFREEZE PROPERTIES TYPES OF CORROSION Atmospheric corrosion or oxidation can occur in the presence of moisture and air—typically a coolant leak onto an aluminium surface adjacent to a hose. Galvanic Corrosion occurs where dissimilar metals, like aluminium and steel in contact with each other, are covered by an electrolyte and effectively become a battery. Crevice corrosion can occur where bolts, gaskets, hoses, clips and crevices, which can be described as dead ends, combine to create a local spot where a coolant may be static so that the beneficial properties are consumed. Cavitation corrosion (sometimes called erosion) occurs where the coolant operating pressure is below its vapour pressure and causes local boiling. According to Owen Falcon, Marketing Director, V8 Super Engines, “It is simple, the head gasket seals combustion pressure and the coolant is transferred from the rear of the block to

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Traditional A/F feature is provided by Mono Ethylene Glycol (MEG); when mixed with water at a concentration of 10%, the freezing point is -4°C falling to -35°C at a 50% concentration. A 50/50 mixture is recommended. Typical MEG concentration in undiluted A/F is 95%. The remaining 5% consists of inhibitors that provide corrosion protection for aluminium alloys, cast iron, steel, brass, copper and lead solder. Traditional A/F formulations are also known as Inorganic Additive Technology (IAT). The same coolant provides enhanced summer time performance. Effects of radiator pressure cap: At a 50% A/F concentration with a 15 psi radiator pressure cap, the boiling point is 129°C at sea level, raw water boils at 121°C at sea level with a 15 psi pressure cap. Water properties: Water properties vary depending on where one lives in the

ANTIFREEZE COOLANTS

UK, east of a line roughly from Dorset to Northumberland water is classed as hard; or above 200 ppm calcium carbonate combined. Alkaline properties: This is important for a coolant in order for it to work successfully to prevent a galvanic attack. Alkalinity is reported as ‘ph’. A ph of seven is neutral. For a new coolant, the typical alkaline range is 8.5–10.5. An old coolant might be lower than ph seven making it acidic or an electrolyte, which supports galvanic corrosion that is not desirable. Colour: Coolant’s A/F colour is another variable—the earliest brand was blue, now it is possible to find green, orange, pink and red as well as brands that change colour should a combustion leak to coolant occur. Colour is no guide to formulation, whether it is IAT, OAT or HOAT; it is best to read the information on the can or a data sheet to determine its type. Specific gravity: It is possible to measure specific gravity with a hydrometer to determine concentration of A/F. Usually, specific gravity is quoted at a normal temperature of 20°C, correction tables are used if the coolant temperature is not 20°C. Users must first determine the specific gravity of the brand and calculate how much concentrated A/F to add to get back to 50/50. It is easier to fix the leaks and then top up with 50/50. If good maintenance practice is followed, then the concentration should not be in question. One more thing to be noted is that raw water for top up should not be used. System pressure: Under normal road running conditions, it is unlikely that the pressure in a cooling system ever exceeds 6 psi. This is because ambient temperature rarely exceeds 20°C—high engine load is rarely sustained for very long periods and so, the circumstances for stabilised conditions do not exist long enough to reach the very high temperatures needed to create high pressure. Plus, once 30 mph is achieved, the air passing through the

radiator provides plenty of cooling air to reduce coolant temperature and therefore, system pressure. The most likely high coolant temperature and pressure conditions are under light load in slow moving traffic or when idling at rest.

ORGANIC ACID TECHNOLOGY (OAT) Modern coolants using OAT are regarded as less toxic than traditional A/F because their active corrosion inhibiting ingredients are biodegradable. This product is aimed at modern engines and extended service intervals.

HYBRID ORGANIC ACID TECHNOLOGY (HOAT) HOAT is available and combines selected features of both IAT and OAT. Marketed as long or extended life, they are already diluted with de-ionised water and are ready to use straight out of the container. They are aimed at extended service intervals.

CORROSION INHIBITING MECHANISM Both kinds of A/F mixture depend on MEG or MPG for their low and high temperature properties, but the corrosion inhibiting mechanism is different. Traditional IAT A/F coolant mixtures deposit their inhibitors on all cooling system surfaces and so,

SOME RECOMMENDATIONS FOR USERS OF COOLANTS When changing a coolant, use a 50/50 mixture of traditional A/F and water. Select a brand that is suitable for classic cars, the main constituent will be either mono ethylene glycol or mono propylene glycol. Never top up with raw water. Do not mix different brands of A/F because formulations vary and may not be compatible. So, follow the manufacturer’s advice. Change the coolant every two years or at the interval recommended.

the depletion rate is faster than with OAT, which is believed to inhibit a corrosion site in the engine after the corrosion has begun. Hence, its depletion takes longer. To this, Falcon adds, “A very strong system pays to do the maintenance of the corrosion and service requires keeping it that way.” Silicone hoses have been cited as being susceptible to attack by OAT coolant. Manufacturers of such hoses know of failures and believe that some hoses of inferior quality may be at risk because of the silicone formulation. Poor, low-grade fillers can absorb coolant and leaks may follow in such cases. High-grade polyester reinforced silicone hoses are just as robust and unlikely to leak as they ever were.

FILLING PRACTICE It is recommended to always fill the cooling system through the radiator and then check and adjust the expansion tank level after the engine has been run to thermostat opening temperature. It is advisable never to open the pressure cap on the expansion tank until the engine has cooled down, hot coolant under pressure can hurt the user. Radiator and expansion tank coolant level should always be checked when the engine is cold. The reason for this is that a 50/50 coolant has three times the expansion rate of water.

COOLANT CONSUMPTION The cooling system is effective and robust. So, if users are experiencing high coolant temperature or high coolant consumption, they should look at the easily available products first. Fixing leaks may need new parts if the hose connection corrosion is severe. The thermostat should be checked to see when the top hose starts to get hot within a few minutes after being idle. The pressure cap’s sealing properly should be checked. Venting the engine to get rid of trapped air should be taken care of. The heater control must be set to hot while the engine valve is wide open.

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3D MODELING AND RAPID PROTOTYPING OF A CRYOGENIC LIQUEFIER

PRATEEK SUR

iquefaction of gases is always done by refrigerating the gas to a temperature below its critical temperature so that the liquid can be formed at some suitable pressure below the critical pressure. The liquid, in most of the

the compressor inlet to repeat the cycle. The purpose of the countercurrent heat exchanger is to warm the lowpressure gas prior to recompression and simultaneously to cool the high-pressure gas to the lowest temperature possible prior to expansion. Both refrigerators and liquefiers

of a refrigeration system, the mass of the gas getting cooled and warmed are equal. This is called balanced flow condition. Though the thermodynamic principles behind both refrigeration and liquefaction are same, the analysis and design of these two systems are different because of the

Coolant enhancement via liquefaction

Our country is dependent on imports for cryogenic refrigerators, coolants and liqueﬁers, which are proprietary in nature and therefore, are very expensive in terms of cost and maintenance. With support from the Department of Atomic Energy, companies might start, develop and study nitrogen liqueﬁer of intermediate capacity in the range of 10–50 litres/hr by using technologies already developed in our country. This would reduce the dependence of the nation on foreign imports for them. Let’s have a look at how cryogenic liquefaction, formed via 3D Modeling and Rapid Prototyping, can help enhance, if not replace, the engine coolant...

cases, is the coolant that is used. Thus, gas liquefaction is a special case of gas refrigeration and cannot be separated from it. In both cases of liquefaction and refrigeration, the gas is first compressed to an elevated pressure in an ambient temperature inside a compressor. This high-pressure gas is passed through a countercurrent recuperative heat exchanger to a throttling valve or expansion engine. Upon expanding to the lower pressure, cooling may take place, and some liquid may be formed. The cool, low-pressure gas returns to

operate on this basic principle. In a gas liquefying system the liquid constantly accumulates and it is withdrawn and stored in other places. However, in the case of a continuous refrigeration system, there is no accumulation or withdrawal of refrigerant needed. Thus, the total mass of the gas in a liquefying system that gets warmed in the countercurrent heat exchanger is less than the mass of gas that is to be cooled by an amount of gas that got liquefied. As a result, there is an imbalanced mass flow in the heat exchanger. But in the case

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condition of balanced mass flow in refrigeration and unbalanced flow in liquefying system. According to Nikhilesh Bishoyee, Junior Asst Prof, Department of Mechanical Engineering, National Institute of Technology, Rourkela, “Low temperature can be produced by the throttling process, but it depends upon the Joule-Thompson (J-T) coefficient. J-T coefficient is a property of each gas that depends upon pressure and temperature; it can have a positive, negative or zero value. For instance, gases like hydrogen,

3D MODELING AND RAPID PROTOTYPING OF A CRYOGENIC LIQUEFIER

helium, and neon have negative J-T coefficients at ambient temperature. So, to be used as refrigerants in a throttling process they should first be cooled by a separate pre-coolant liquid. Then, the throttling process can be applied for further cooling; otherwise it will heat these gases.” Bishoyee continues, “There is another method for producing low temperature which is the isentropic expansion of the gas through as an expansion engine. In the ideal case, the expansion is generally reversible and adiabatic and therefore, the process is isentropic. In this case, the isentropic expansion can be defined as the coefficient which expresses the temperature change due to a pressure change at constant entropy.” Bishoyee adds, “The isentropic expansion through an expander always results in a decrease in temperature, whereas an expansion through an expansion valve may not always result in a temperature decrease. In the isentropic expansion process, energy is removed from the gas in the form of external work, so this method of lowtemperature production is sometimes called the external work method.”

RAPID PROTOTYPING Advantages Production of parts is faster and less expensive Material savings in comparison to other methods Product testing is quickly possible Design improvements can be achieved Error elimination from design can be fast Experiments can be done on physical objects of any complexity in a short period of time Using a prototype development of a system can be done with less effort in comparison to development without prototype Labour cost due to manufacturing, machining, inspection and assembly is reduced Reduction in material cost waste disposal cost, inventory cost, material transportation cost Design misinterpretations can be avoided Quick design modification is possible Better communication between the designer and user because of 3D presentation of the model to be prototyped. Disadvantages According to some, RP is not an effective model of instructional design because it does not replicate the real thing Many problems may be overlooked that results in endless rectification and revision Rushing in to develop a prototype may exclude other design ideas Design features may get limited because of the limitation of the prototyping tool Sometimes the prototyping machine may not deliver product up to expectation The system could be left unfinished due to various reasons or the system may be implemented before it is completely ready The producer may produce an inadequate system that is unable to meet the overall demands of the organisation.

THREE-DIMENSIONAL (3D) MODELING 3D modeling is the process of developing a mathematical representation of any three-dimensional surface of an object by the use of specialised software. The product is called a 3D model. It can be displayed as a two-dimensional image through a process called 3D rendering or used in a computer simulation of physical phenomena. The model can also be physically created using 3D Printing devices. Almost all 3D models can be divided into two categories, which are: Solid: These models define the volume of the object they represent (like a rock). These are more realistic, but more difficult to build. They appear to be the same as a surface model, but have additional properties, such as weight, density

and centre of gravity, just like that of a physical object. These models are commonly used as prototypes to study engineering designs. Solid models are mostly used for non-visual simulations such as medical and engineering simulations and for Computer Aided Design (CAD) and specialised visual applications such as ray tracing and constructive solid geometry Shell/boundary: These models represent the surface, e.g. the boundary of the object, not its volume (like an infinitesimally thin eggshell). A 3D surface is like a piece of paper that can have any dimension and can be placed at any angle to define a shape. Just like a

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paper model, different surfaces can be joined to form a surface model. These are easier to work with than solid models. Almost all visual models used in games and film are shell models.

RAPID PROTOTYPING Rapid prototyping (RP) is a process that can be used to produce solid models from CAD data. It is a method that uses new manufacturing technologies to produce parts on a layer by layer method. Using this method, complex parts can be manufactured quickly and costeffectively as well. As the time taken is less compared to other methods, it is called RP. Elaborating further, Bishoyee comments, “RP

3D MODELING AND RAPID PROTOTYPING OF A CRYOGENIC LIQUEFIER

REQUIREMENT OF NITROGEN LIQUEFIER Nitrogen liqueﬁer is used to produce liquid nitrogen. Liquid nitrogen is the commonly used cooling medium because of its low production cost and relatively higher levels of safety. The various application areas of liquid nitrogen are: As a pre coolant in production of liquid helium and other low temperature refrigerators. Cryotreatment of critical metallic components such as, milling cutters, rollers, needles, dies and punches, knives, bearings and other precision measuring equipments. Preservation of live biological material as blood, animal and human sperms & embryos, human parts, etc. Miscellaneous industrial and laboratory applications. technologies and rapid manufacturing technologies offer great potential for producing models and unique parts for manufacturing industry. Use of RP increases the reliability of the product and saves time & money.”

WORKING PRINCIPLE BEHIND RAPID PROTOTYPING Although several rapid prototyping techniques exist, all employ the same basic five-step process. The steps are: Creation of the CAD model of the design Conversion of the CAD model to STL format Slicing the STL file into thin crosssectional layers Layer by layer construction Cleaning and finishing the model.

RAPID PROTOTYPING PROCESSES RP refers to a class of technologies that can automatically produce solid models from CAD data. It is a freeform fabrication technique in which the object of a prescribed shape, size, dimension and finish can be directly constructed from the CAD-based geometrical model stored in a computer, with little human intervention. The fabrication processes in a RP can basically be divided into three categories—additive, subtractive and formative. In the additive or incremental processes, the object is divided into thin layers with distinct shape and are

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then stacked one upon the other to produce the model. The shaping method of each layer varies for different processes. According to Bishoyee, “Most of the commercial RP systems belong to this category. Such processes can also be called Layered Manufacturing (LM) or Solid Freeform Fabrication (SFF). Layer by layer construction method in LM greatly simplifies the processes and enables their automation. An important feature in LM is the raw material, which can be either one-dimensional (e.g. liquid and particles) or two-dimensional (e.g. paper sheet) stocks. In the case of subtractive RP processes, 3D raw material stocks are used. Stereolithography Apparatus (SLA), three-dimensional printing, Selective Laser Sintering (SLS), Contour Crafting (CC), Fused Deposition Modeling (FDM), and so on, are a few examples of LM. Subtractive or Material Removal (MR) processes uses the method of cutting of excessive material from the raw material stocks.” Bishoyee adds, “There are not as many subtractive prototyping processes as that of additive processes. A commercially available system is DeskProto, which is a 3D Computer Aided Manufacture (CAM) software package for RP and manufacturing. As in case of pure subtractive RP processes, the model is made from a single stock, fully compact parts of the

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same material as per actually required for end use is possible.” Elaborating further, Bishoyee explains, “The other advantages like accuracy of the part dimensions and better surface quality can be achieved by the subtractive machining approach.” “However, if we compare geometric complexity, the MR processes are limited than the LM processes. Different types of cutting methods used are Computer Numerical Control (CNC) milling, water-jet cutting, laser cutting, etc. In formative or deforming processes, a part is shaped by the deforming ability of materials. At present, there is no commercial forming-based RP system in the market. In case of LM process, the geometric complexity of objects is relaxed up to a significant extent due to the layer by layer manufacturing. Some features which are difficult to obtain using MR process can be achieved using LM process. Raw material is one of the limitations in case of LM process. Both the LM and MR processes can be integrated to obtain more benefits,” Bishoyee avers. This integration creates a hybrid RP system which can produce better surface quality without tempering the manufacturability in case of complex features.

THE WAY AHEAD Cryogenic liquefaction is based on a suitable modified Claude cycle that minimises the number of heat exchangers and also takes care to accommodate the in-house developed turbo expander. The thermodynamic parameters (temperature, pressure, and pinch point temperature) & rate of mass flow are evaluated to obtain the required designing specifications for each component. By using 3D modeling and RP all the coolants, presently used, can get replaced to a higher & better version. prateek.sur@network18publishing.com

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Pg No. 102

NEW AGE MAINTENANCE TECHNOLOGIES

How painful is flushing the

LANT out?

There are a couple of service jobs people probably see fairly often involving the vehicle cooling system. One is finding and fixing intake manifold gasket coolant leaks on General Motors V6 pushrod engines; the other is draining and filling the system on a host of cars, trucks and SUVs. Let’s take a look at both of these operations and find out what to do and what not to do when the coolant is to be flushed out... PRATEEK SUR

n theory, draining and filling the cooling system should be straightforward, but on most vehicles, it has become a beast of a job. The situation is getting worse, as companies come up with more vehicles having complex coolant flow paths. Furthermore, the long coolant service intervals recommended by all manufacturers nowadays means that the coolant usually is in great need of replacement when the motorist finally does decide to get the job done. Often, this decision is made because a hose or gasket joint has been leaking, and the system has been topped up periodically with who-knows-what in terms of antifreeze. In most cases, the motorist uses tap water of unknown quality. It is recommended for a first drain & refill step is to check both the coolant level and the concentration. Next, the system should be pressure-tested and inspected for any leaks, followed by repairing. If there is evidence of leakage, but it cannot be detected, the motorist should pour trace dye into the system and drive for a few days to circulate it.

DYE COOLANT In a relatively late-model vehicle, if

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the coolant is close to the marked level in the reservoir, is topped up in the radiator (if there is a way to check that), looks clean and the refractometer says the mixture is within a whisker of 50-50, those are good signs. The coolant may be ready for a change, but at least it probably has not been badly contaminated since it was installed at the factory. The motorist may admit to some do-it-yourself service that can change common opinion. In fact, if a motorist sees an antifreeze dye color that does not match what is expected in the OE coolant, s/he should for sure ask from the manufacturer. Paul Weissler, award-winning journalist, former technician and a recognised expert on automotive heating & air conditioning with over 40 years experience in the automotive service industry, says, “Dye color does not mean anything from the standpoint of antifreeze performance, but it might indicate that there is some crosscontamination; or it might not. The aftermarket replacement for DexCool could be yellow (Prestone), not orange/ pink. The aftermarket replacement for Chrysler’s orange is yellow (Zerex G-05 or Havoline Custom Made). One aftermarket replacement for all

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Asian formulas is Zerex Asian Vehicle Long Life, which is pink. Everything could be fine, but the more information a motorist has, the better job can be done.” There are some shops that flush every system and replace with conventional American green, a twoyear formula, not the OE extended-life antifreezes.”

UGLY TRUTH It is impossible to fully drain a cooling system on almost any modern car or truck with a procedure short of pulling the engine, turning it upside down and tilting it. And with all the nooks & crevices, motorists are not even sure if it would work on all engines. The second surest way to drain a modern cooling system is to use a premium drain & fill machine, which will probably replace 85–90% of the coolant. Third best is to drain the radiator and block (which may involve disconnecting the lower radiator hose). This would draw all the coolant out of the reservoir and run water through the heater until it runs clear. Then, fill the system as full as possible, including the reservoir, warm up the engine and let it cool down, then fill with plain water and top up. To this, Weissler adds, “Special funnels

NEW AGE MAINTENANCE TECHNOLOGIES

that fit in the radiator neck are helpful if there actually is a radiator fill neck. But with fewer vehicles these days, having one such funnel has limited value. The by-the-book percentage procedure is to repeat the cool-down/ warm-up and then drain & fill twice more. That should get about 90% of the old coolant out of the system.” Then, get enough water out of the system, perhaps there is enough in the radiator and reservoir, to add enough antifreeze for a 50-50 mix.

RECOMMENDATIONS If the cooling system has an inlet thermostat, make it standard procedure to pour in fresh coolant through the upper radiator hose. However, if the stat is in the cylinder head at the outlet to the radiator, the motorist will have to remove the thermostat first. But then the results are a responsibility of the motorist. Bottom line, as Weissler puts it, is, “This is not going to happen, not in any repair shop I have visited lately.” Maybe a dedicated do-it-yourselfer with a spare weekend will do a tripledrain/thermocycle/refill. The fact is that a triple drain, thermocycle and refill would likely tie up a service bay for a full day (even if the technician is not actually working on the system more than an hour total). The technician will drain the radiator, maybe disconnect the lower hose and suck the coolant out of the reservoir with a drain & fill machine ‘wand’ or venturi vacuum cooling system kit, if the technician has one. Then, the technocian will do his best to fill the system. If the technician does not get it adequately drained, the left-in debris will restrict the heater and/or radiator. If the technician does not get it completely filled, the system will have air pockets, so it may not cool properly in summer or provide adequate heat in winter.

A FRESH FILL FOR THE SYSTEM? A drain & fill machine, with the flushing feature, still is the best choice. There are several choices from large,

reputable manufacturers. The lineup of major suppliers includes FloDynamics, Motorvac, Yellow Jacket (Ritchie), Robinair, Bosch/RTI Technologies, Snap-on, Viper (Clore Equipment) and Wynn’s. Commenting on the same, Weissler avers, “Manufacturers typically offer a full line of choices. Some basic machines may be designed to simply draw the coolant out of the radiator, but the manufacturer also will offer full-feature drain & fill equipment, with backflush adapters. And they would be our choice. What also makes the right machine a superior choice is that you can use a 50-50 mix that includes distilled or de-ionised water. There is nothing that can beat the treated water, which is what they use in the 50-50 mix. Of course, you pay almost as much for 50-50 as you do for pure antifreeze, so it is really not an economical purchase. It is one of the secrets behind the long coolant intervals that carmakers specify for new systems: no debris, a perfect fill & brand-new gaskets and hose connections”. By the time the vehicle gets to the shop, the factory-fill 50-50 mix could be anything, which is why it is always suggested that the technician checks the concentration before they even start servicing the system. Weissler adds, “The second choice is to drain as completely as possible, typically the radiator, engine and the reservoir, but maybe not as much as the motorist might get out.”

EXCEPTIONS If the coolant is old and there seems to be a restricted heater, leaving the coolant in the heater does not do the system any good. Backflushing with water helps—at least the core will remain filled. In fact, if the coolant is dirty, a drain & fill machine with a flush feature is about the only way to clean out the system. The motorist can try chemical cleaners, but then they have to get them out, and then again, a machine is the only singleprocedure approach that has a chance

in this. One flushing device, the Hecat coolant pulsator, uses a hammer-like delivery of water and shop air. Cooling system specialists opine that it often clears enough plugging to restore reasonable performance, if not the performance level of a new core. So a vacuum refill of the heater core follows this procedure and would be worth the effort. “Of course, we recognise that heater performance is a winter service issue, so unless the motorist also says that the heater did not work in winter and wants the technician to do something now, the technician cannot justify going overboard in midsummer. The motorist could ask, or even check heater operation, but that’s about it,” opines Weissler.

WHAT NEEDS TO BE DONE? Without the drain/flush/fill machine, when it is time to fill, the technician would have to do everything right. If the vehicle is an SUV or minivan with a rear heater, and there has been a leak that was repaired, there is an obvious problem when the motorist jacks up the front of the vehicle to help bleed air from the front end. The rear heater will be below the front of the vehicle and never bleed air. The only answer is to fill the rear heater separately, and that is true even when the technician is servicing the system with a machine. “For the front system, one standard operating procedure, of course, is to open all the air bleed valves and start filling. Although some air bleeds are in plain view and accessible, others take some looking for, including checking the vehicle service information. It is advisable to open the bleeds. Next, run the engine at idle so air bubbles will rise to the surface of the coolant, and top up slowly. If the radiator has a fill neck, use a funnel, which allows coolant to flow into the system as air bubbles rise out from the neck. When the technician sees solid streams of coolant from the bleed valves, s/he should close them and finish topping up,” concludes Weissler.

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VACUUM DISTILLATION TECHNOLOGY

Recycling Gets Tech Advantage Millions of gallons of waste engine coolants are generated each year during routine preventative and other maintenance procedures. A signiﬁcant percentage of this waste is generated by vehicle ﬂeet operations. Waste glycol that was routinely dumped down the drain is now being recycled on-site using sophisticated vacuum distillation technology. Waste engine coolants are basically composed of water, ethylene glycol (or occasionally propylene glycol), brokendown corrosion inhibitors, corrosion byproducts and possibly heavy metals. Here are some ways to do away with this increasing waste of engine coolants by using vacuum distillation technology... PRATEEK SUR

he disposal of used coolant in the automotive industry can be costly when managed as per the legislative requirements. Recycling systems that convert used or contaminated coolant into a suitable product for re-use can, under certain circumstances, do so at a lower cost than the approved disposal. Many shop floors use coolant-recycling systems nowadays, such as Vacuum Distillation Technology (VDT), and recycle between 50% and 100% of used coolants reducing their purchase and disposal costs that would normally have been an extra cost to customers. VDT is a method of distillation where

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the pressure above the liquid mixture to be distilled is reduced to less than its vapour pressure (usually less than atmospheric pressure) causing the evaporation of the most volatile liquid(s) (those with the lowest boiling points). This distillation method works on the principle that boiling occurs when the vapour pressure of a liquid exceeds the ambient pressure. Vacuum distillation is used with or without heating the mixture for recovering the engine coolants that go waste.

SENDING WASTE ENGINE COOLANT DOWN THE DRAIN IS UNDESIRABLE Ethylene glycol requires large quantities of oxygen to be broken

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down during the sewage treatment process. Sewage treatment plants require a proper oxygen level to efficiently process sewage. Waste engine coolant can upset this delicate oxygen balance. The bulk of the inorganic corrosion inhibitors, broken-down corrosion byproducts and heavy metals settle into the sludge that is periodically hauled from the sewage treatment plants. This sludge may exhibit toxic characteristics in part due to processing waste coolants. Ethylene glycol itself comes from non-renewable resources. Every effort is being made to recycle this valuable material.

VACUUM DISTILLATION TECHNOLOGY

AUTOMOTIVE INDUSTRY: EXISTING COOLANT MANAGEMENT PROCESSES There are several ways to dispose of waste coolant. These include: According to environmental agencies guidelines, the only way to dispose of waste coolant is to store it in dedicated drums and to have it removed by a licenced waste contractor. The price for the disposal of waste coolant varies from location to location for any business, volume per annum, irrespective of whether the business is using the same contractor for other waste streams. The approximate price for waste coolant disposal—if the same waste contractor is used to remove waste oil, used solvent and other automotive waste—is about $90.00 per 205-litre drum in the international market. A common, but not condoned, practice for coolant disposal is to include it with used oil and then get it removed by a waste contractor. The price for used oil removal ranges from no cost to up to $220 for 1,000 litre internationally. Economically, this is a more attractive option than having it removed separately, but waste coolant contaminates used oil, thereby reducing the quality of the product for recycling. In some circumstances, waste coolant is also disposed of to sewerage. Sewerage treatment plants often do not have the ability to remove some of the contaminants and pollutants associated with coolants, including small amounts of heavy metals, glycol and other additives. Because of this, these pollutants remain in the water after treatment and are discharged to areas such as farms, golf courses, industry, rivers and the ocean. The quality and quantity of wastewater discharged to waterways is regulated by the environmental agencies. Disposing of coolant to sewerage is

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not allowed under government rules and could result in the loss of licence and ability to dispose of the sewerage plant. Another unaccepted but relatively habitual practice is to dispose waste coolant to stormwater drains. Stormwater drains are designed for rainwater only and not for the disposal of liquid wastes. Stormwater is not treated prior to its discharge to rivers, oceans, lakes and groundwater. If caught, severe fines may be issued by environmental agencies to businesses discharging such waste coolants.

VACUUM DISTILLATION TO RECYCLE WASTE COOLANT Simply put, VDT system provides the highest quality recycled coolant available. Distillation has been used for many years by the industry to recover valuable waste solvents created during the manufacture of most of the products we use every day. Finish Thompson Inc is one of the primary organisations which is promoting this new VDT. Daniel Roll, VP – Engineering and R&D, Finish Thompson Inc, says, “Finish Thompson’s advanced vacuum

ADVANTAGES On-site recycling using VDT provides the following beneﬁts: Allows for the recovery of a valuable non-renewable resource Helps protect sewage treatment plants Removes virtually all contaminants, both suspended and dissolved Removes excess water from waste coolant providing concentrated glycol Produces high-quality, reusable water that is free of unwanted dissolved solids Is an OEM-approved process Reduces coolant costs and saves money Reduces long-term liabilities associated with coolant disposal.

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distillation technology has been tested and approved by numerous automotive & heavy duty OEMs and has been proven to produce the highest quality recycled coolant available. Our distillation process excels at removing suspended and dissolved solids (broken-down corrosion inhibitors, dirt, rust, etc.) & heavy metals and it is the only process that allows the removal of excess water.”

SPECIAL CHALLENGES FOR HEAVYDUTY VEHICLES USERS Heavy-duty vehicle users (18-wheelers, construction equipment, military vehicles, etc.) face an extra challenge owing to the widespread application of the addition of Supplemental Coolant Additives (SCAs) to the engine coolant on a regular basis. SCAs are usually added to help avert cylinder sleeve erosion. Regrettably, these result in a coolant with higher dissolved solid levels compared to automotive engine coolants. Ultimately, the level of dissolved solids can reach a point where the liquid attains a saturation point and the solids begin to dropout (particularly when the engine is off and exposed to cold temperatures, a liquid’s capability to keep solids dissolved reduces as the temperature falls). This can cause troubles such as water pump seal failure and jamming of radiator passages. “Vacuum distillation is the preferred method of recycling waste engine coolants by heavy-duty users due to its ability to remove virtually all solids, both dissolved and suspended. This process results in a recycled coolant that is virtually identical to a new one,” avers Roll.

WATER QUALITY ISSUES Waste coolant typically contains surplus water (more than 50%). Advanced distillation technology is the only method on the market that eliminates excess water and makes a concentrated clean glycol. Talking about the necessity and quality of water, Roll articulates, “VDT has

VACUUM DISTILLATION TECHNOLOGY

WHY USE AN ENGINE COOLANT? Concentrated anti-freeze generally consists of 95% ethylene glycol, 3% corrosion inhibitors and 2% water. Engine coolant is typically a 50/50 mixture of concentrated anti-freeze and water. This mixture is critical to the performance of modern combustion engines. A proper concentration of coolant provides protection against freezing in low temperatures when the engine is not operating and also helps prevent boil-over during hot weather (the 50% ethylene glycol lowers the freezing point and raises the boiling point). One of the most important functions of quality engine coolant is the protection of internal metallic engine components from corrosion. Modern engines contain various metals including iron, brass, copper, and increasingly aluminium. Without proper corrosion protection, these metals can quickly get corroded causing premature damage/failure of engine and cooling system components. Aluminium is being increasingly used in engines to save weight, helping vehicle manufacturers meet strict fuel economy standards. Unfortunately, aluminium is a reactive metal that is easily affected by a coolant that has depleted corrosion inhibitors. Failure to maintain and change engine coolant according to the manufacturers’ recommendations can result in internal engine and component damage. the added benefit of dramatically improving water quality by producing a high-quality, reusable water stream. The customer can add this distilled water to the concentrated recycled glycol to produce an even higher quality 50/50 coolant mixture.” Coolant is 50% water, and, therefore, water quality is important in a coolant. The vast majority of engine coolant is mixed with ordinary tap water. While tap water may look clean, it contains unwanted minerals. Water quality varies dramatically throughout the country. Distilled water is superior to tap water because it is free of these unwanted minerals. The minerals found in tap water provide no beneficial effect and only serve to raise the level of dissolved solids in the coolant increasing the likelihood of forming precipitates. Most vehicle manufacturers recommend using distilled or low-mineral content water when mixing coolants.

DISTILLATION PROCESS WORKING The BE-55C vacuum distillation system needs the least amount of operator participation. Once the unit is packed with waste coolant and on track, the unit can operate virtually unattended until the process

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is complete. Following is the normal sequence of operation for a waste coolant run in the BE-55C: Fill: The fill/drain hose is inserted into a 55-gallon waste coolant drum. A fill switch on the BE-55C starts a vacuum pump. As vacuum is formed in the process tank, the fill valve is opened to draw in the waste coolant. When the drum is emptied, the operator switches the fill off. A sensor prevents more than 55 gallons from entering the process tank. Water Process: The start switch is depressed and heat is applied bringing the waste coolant to a boil inside the distillation tank. A waterrich vapour is first formed, as water lowers boiling point (compared to ethylene glycol). This vapour passes through a heat exchanger where the vapour is turned into a clean water stream that can be reused to make new coolant or drained. The distilled water gravity drains into the processed water-receiving drum. Glycol Process: When most of the water has been processed, the temperature inside the process tank will begin to rise. When this temperature reaches 280°F, a switch closes, energising the vacuum pump

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and the divert solenoid valve. At this point, the upper heaters de-energise and remain off for the remaining part of the cycle. During this portion of the process, the glycol is vapourised under a vacuum (reducing its boiling point). The distilled glycol gravity drains into the processed glycol-receiving drum. Auto Shutdown: The BE-55C automatically terminates the process when the liquid in the process tank reaches a low level. This low-level sensor de-activates the ‘process on/ off switch’, shutting the unit off. Drain Assist: After the cycle is complete, the residue is drained into a residue collection drum. The fill/drain hose is placed into this drum, the fill/drain valve is opened, and the drain assist switch is depressed and held (activating the air supply solenoid) until the residues stop flowing. Inhibit: After the process is complete, the recycled coolant can be mixed with processed water to obtain the desired freeze/boil protection and inhibited with Finish Thompson’s Premium Inhibitor to restore the glycol to a like new condition.

COSTS OF RECYCLING USING VDT “Not only does vacuum distillation provide the highest quality recycled ethylene glycol possible, but it can be one of the most economical as well. There are no filters, resin beds, freeze point adjusters, flocculants and other chemicals to purchase and inventory in order for the process to work. All that is required is the distillation system, inhibitor and waste coolant,” concludes Roll. Vacuum distillation can recycle coolant (50/50 mixture of clean inhibited glycol and water) so that it can be reused again. When the disposal costs for waste coolants are uncertain, the long-term liabilities associated with the disposal of waste coolants remain unknown. However, using VDT makes recycling startlingly affordable.

SIEMENS’ NX™ DIGITAL PRODUCT DEVELOPMENT SYSTEM

Delivering the world’s most

Powerful Diesel Engine JCB, which had been sourcing diesel engines manufactured by third-party engine suppliers to power its construction vehicles, was faced with the challenge of meeting the customised requirements of its customers. As a result, the company decided to develop its own engines. Following the successful launch of JCB444 diesel engine with the deployment of Siemens’ NX™ digital product development system, JCB developed a high performance version, the world’s most powerful automotive diesel engine per litre. CB, one of the world’s leading construction equipment manufacturers, has a long heritage of supplying innovative products. To power its construction vehicles, the company had traditionally relied on sourcing diesel engines manufactured by third-party engine suppliers. However, in its ongoing quest to further increase customer satisfaction, the company decided to develop its own engines, exclusively designed to suit the specific requirements of its construction products.

A TRIED AND TESTED PRODUCT DEVELOPMENT PLATFORM For over 17 years, JCB’s long-term product development strategy relied

ADVANCED ASSEMBLY SUPPORTS SIMULTANEOUS WORKING

THE CHALLENGE OF INNOVATING IN A NEW AREA While having previously built prototype diesel engines, it was a bold move for JCB to start production of its own engines. For the company to maintain the continued trust of its customers and to command the respect of the industry, it needed to ensure that any move into engine production was a complete success, from the introduction of its very first engine. With this in mind, the company initiated an extensive new product development process, starting with a detailed feasibility study that incorporated concept design, testing and manufacturing planning. From the outset JCB worked in close cooperation with a chosen group of partners and probable suppliers, including technology partner, Ricardo Consulting Engineers.

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virtual and physical testing process to produce the finished complex 3D model. Data from the NX solid model was used to manufacture final components and facilitate a successful first launch.

on Siemens’ NX™ digital product development system. As a tried and tested platform familiar to the company’s design engineers, it made sense that NX would be the software chosen to drive the development of its diesel engines. NX supported the creation of the initial concept designs for JCB’s first engine, the JCB444, and enabled the development team to take their early ideas through the rigorous

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During the initial feasibility study and the subsequent product development phase, between 10 and 20 design engineers from JCB and Ricardo were working on the JCB444 project at any one time. This process was facilitated by NX advanced assembly techniques as Alan Tolley, Director – Engine Programs, JCB, explains, “From the outset, NX enabled us to incorporate all the components making up the eventual 3D model of the engine into a single assembly file that everybody on the development team worked within. We were all working in context. Changes made to an individual part design by one engineer would be visible to every other engineer, thereby helping to ensure that the interrelated parts would ultimately fit together.”

PREDICTIVE TECHNIQUES ENHANCE ACCURACY Predictive techniques and simulations were heavily used throughout the process to enhance accuracy, reduce the need for rework, optimise resources and support the problem-free introduction

SIEMENS’ NX™ DIGITAL PRODUCT DEVELOPMENT SYSTEM

CHALLENGES

SOLUTIONS

To start production of its own engines while ensuring that any move into engine production was a complete success, from the introduction of its very ﬁrst engine.

NX would be the software chosen to drive the development of its diesel engines. Data from the NX solid model was used to manufacture ﬁnal components and facilitate a successful ﬁrst launch.

of the engine. NX 3D animation sequences enabled the design engineers to analyse the complex motion of the moving engine parts and ensure that individual components would not interfere with each other. The integrity and accuracy of the NX 3D data was crucial to the simulation and virtual testing stages for which it was used in a variety of specialist software packages. This included tools to simulate the forces on different parts of the engine and computational fluid dynamics (CFD) to replicate the flow of fluids through the cylinder head and cooling system. To help assess the ways in which the engine they were developing would eventually be housed within JCB’s range of construction vehicles, the design engineers conducted a series of virtual tests in which solid models of the engine were virtually implanted into 3D representations of the construction products. NX helped to speed progress to the next stage in the product development process— physical trials that involved testing the real-world performance of prototype engines in the construction vehicles. JCB’s component suppliers and specialist prototype manufacturers used the NX 3D data directly in their CNC machining and laserbased prototype machines to manufacture prototype parts. Again, the integrity of data played an important part as it reduced the requirement for supplementary 2D designs or any rework.

PARAMETRIC FEATURES FACILITATE FAST EDITING Each phase of virtual- and real-world testing produced refinements and iterations that NX parametric facilities enabled the design engineers to quickly apply to the 3D model. Edits made to individual components automatically generated corresponding changes to any interrelated parts because NX linked the different elements of the design. This supported the gradual evolution of the engine as the development process progressed towards manufacture of parts and assembly. Courtesy: Siemens Product Lifecycle Management Software Inc.

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Image Courtesy: ABB

ROBOTICS

Enhancing

Lean Manufacturing Environments

Large and small manufacturers stand to beneﬁt immensely from lean manufacturing and robotic automation. With a lower cost, more capabilities and a large number of successful manufacturing implementations, robots can increase return, improve quality, reduce costs and help eliminate waste. raditionally, robots have not played a prominent role in the implementation of lean strategies. However, due to robots’ repeatability, speed, accuracy and flexibility, the role of robots in lean implementations is constantly increasing. Automation equipment, which includes robots, is rapidly becoming a core component to lean manufacturing and the reduction of manufacturing costs. Robotics have made it possible for manufacturers to vastly increase the scale of factory automation over the past three decades. With over 115,000 sold each year, industrial robots have become a mainstay of all sizes and types of manufacturing facilities. This increase in robotic automation has resulted in higher production rates, improved quality with decreased requirements for human intervention, while elevating the nature of work by removing people from dull, dirty & dangerous tasks. Adding robotic automation however, does not automatically make a manufacturing environment lean. Lean manufacturing is a

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management philosophy focussing on reduction of seven manufacturing related wastes as defined originally by Toyota. The wastes are: Overproduction (production ahead of demand) Transportation (movement throughout the process not required to build the item) Waiting (Work-In-Process (WIP) sitting and waiting for the next production step) Inventory (components, WIP and finished product) Motion (people or equipment moving more than required to perform the processing of the part) Over Processing (due to poor tool or product design creating activity) Defects (the effort involved in inspecting and fixing defects). Robots are not innately lean since they could be used to automate a faster creation of waste, but they are often integrated within the manufacturing process to support and enhance lean manufacturing system success criteria such as: Repeatability: Robots drive product quality or consistency and reduce

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waste. Speed: Robots can help increase production and reduce wait time. Accuracy: Robots help to reduce scrap. Flexibility: Robots reduce training and changeover time—with a target of Single-Minute Exchange of Die (SMED), and often achieving OneTouch Exchange of Die, (OTED) goals.

LEAN SYSTEMS AND ROBOTS One thing that often gets overlooked is that automation systems (with or without robots) can actually speed up the creation of waste and reduce profitability if not designed into the system properly. No automation system or robotic solution is by nature lean by themselves. Designing the manufacturing system to be lean is one of the largest challenges faced by engineers today. A few of the factors which must be taken into account while designing a lean manufacturing system with robots are: Allowable scrap rate Conveyor and other transportation requirements

ROBOTICS

Cycle time requirements by station or operation Equipment reliability and downtime statistics Flexibility required in the process Human machine interface requirements Life cycle of manufactured product to ensure acceptable RoI Line automation requirements (% Automation Vs Manual) Line production rate requirement Product handling requirements Maintenance requirements Repair time of equipment Space availability for robotic operations Safety standards and ergonomics guidelines Number of product variants. Traditional production lines are designed to be an effective collaboration between man and machine. While the machines (including robots) can be programmed for optimal performance, people cannot. Effective ‘lean’ robot cells must take this into account. An efficiently designed automated robotic station must take into account the ‘human variable’ and not limit the stations ahead in the line by rigidly ensuring consistent system performance. Most importantly, the decision to use robots must be justified by a Return on Investment (RoI) analysis. Small and large manufacturers have proven today’s robots can significantly improve the RoI in a manufacturing environment, especially when implementing robots in support of a lean initiative— but again, planning is critical. The robots must be properly incorporated into the overall lean manufacturing environment to get the desired results.

CASE STUDIES: ROBOTS IN LEAN SYSTEMS Below are several common examples of robots strengthening a lean manufacturing environment to significantly help drive a positive RoI and support lean manufacturing goals.

Material Handling and Machine Tending Applications (Repeatability and Speed) Prior to robots, material handling and machine tending were purely manual tasks. Operators would transport material from one fixture or machine to the next, wait on the equipment to finish its task, and then relocate the processed part(s) to another tool or process fixture. Several operators were usually required. Today, these labourintensive tasks are often accomplished using robots, especially in operations requiring high speed and accuracy. Many applications, such as baked goods coming out of an oven on a conveyor, are picked and set into their packaging. Then, the individually packaged products are automatically placed into cases, ready to be palletised. The palletising robot can then place cases accurately on the pallet. Each of these robotic applications may be configured specifically for the customer the product is being shipped to. For example, Walmart may have a different packaging and palletising requirement than Costco or Kroger. Each order can be picked, packaged and palletised automatically to meet the customer’s unique requirements. How do robots make the system lean? There is no wait time for operators. A material handling robot can be set up to multi-task, performing additional processing operations between operations. Robots have negligible downtime. Robots deliver a limited production loss compared to manual operations which tend to be error prone and inconsistent in terms of production rate, shifts, work breaks, etc. Robots are less expensive to operate, compared to human labour— especially when overtime is required. Robots RoI can be quickly realised when there is high demand for the manufactured product. Robots are capable of highly accurate, highly repeatable tasks, which result in lowered scrap parts

once the robot tasks are optimised. Robots do not get fatigued and are not subject to heat, dust, humidity and other challenging work environments. Multiple Applications: One Robot (Flexibility and Speed) To incorporate robots into a lean manufacturing environment, engineers should look to process as many operations as possible within the given floor space. Standard industrial robots have a single tool mounted to a single arm, which is more efficient than human labour, but limiting due to the lack of flexibility. Today’s robots can incorporate tool changers to allow the robot to handle more than one task. With one robot now able to perform multiple functions, the manufacturer will see improved utilisation, and has the ability to create a leaner manufacturing environment overall. In the die cast industry, robots are commonly used for material handling parts as well as de-gating and finishing operations like deburring and grinding. Robots, in an automotive body shop, are often used for material handling of parts as well as welding or sealant application. Robots that need to perform more than one function are built with tool changing equipment that can be used for robots to disengage/engage new end-effector tooling. Servo motor driven external axes allow robots to be more flexible by acting as auxiliary axes of motion to ensure maximum robot utilisation. Advances in robotics have given engineers the flexibility they need to incorporate robotics into a lean manufacturing initiative. Robotics have furthered engineering’s ability to optimise operations based on floor space, cycle time and feasibility constraints. Over time, multi-arm robots will become the norm, continuing the progression of manufacturing operations that are faster and leaner. Robots and Vision Applications (Flexibility and Accuracy) Vision technology and robots are a

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ROBOTICS

TEN BENEFITS OF ROBOTS IN LEAN MANUFACTURING The following list is based on research conducted by the International Federation of Robotics (IFR): Reduce operating costs: Robots are cheaper to operate compared to humans. Energy savings can be significant due to lowered heating requirements in automated operations. Current estimates point to a potential 8% savings for every 1OC decrease in temperature. Savings of 20% can be achieved by turning off unnecessary lighting in automated areas. Improve product quality and consistency: Robots are inherently accurate and have a high degree of repeatability. The risks of errors caused by human factors such as tiredness, distraction, or the effects of repetitive and tedious tasks do not affect robots. This results in improved end product quality. Improve quality of work environment for employees: Robots can take over tasks that are hazardous for humans thereby improving working conditions. Staff motivation can also be improved by training them to take on more technically challenging applications involving robots. Increase production output rates: Robots can be left running for long shifts, overnight, and during weekends with little supervision. This enables true 24-hour production runs to increase output levels. New products can be introduced faster into the production process. Programming of new products can be done offline with no disruption to existing process. Increase product manufacturing flexibility: Switching from one process to another is very simple with robots. Consequently, systems with robotic automation can accommodate variations in product and process resulting in maximum RoI on capital investment. The development in vision systems for robots has resulted in a huge increase in the flexibility of robot usage. Reduce material waste and increase yield: Robots perform routine functions to fine tolerances reducing rejects and scrap waste. Improved accuracy from using robots means you can have more products finished first time to the quality standard demanded by your customers. Comply with safety rules and improve workplace health and safety: Robots can take over tasks in conditions that are hazardous to human workers. Robots can also handle tasks that if done manually, could lead to ailments such as Repetitive Strain Injuries (RSI) or vibration white finger. Welding environments are inherently hazardous for human eyes; this safety issue can be avoided by using robots. Tasks that are ergonomically challenging could potentially be handled by a robot, thereby improving the plant safety record. Reduce employee turnover and improve recruitment: Running a manufacturing plant with automation requires a technically skilled workforce. The work is challenging and the associated problem-solving requirements make the tasks intellectually stimulating. Consequently, employee turnover is reduced and the facility attracts high quality employee candidates. Reduce capital costs (inventory and work in process): Robots are a costeffective option to manual manufacturing. The RoI from using robots is quicker than manufacturing with operators. Robots can be programmed to produce products on a just-in-time basis, thereby reducing the amount of inventory or work in process product. Save space in high-value manufacturing areas: Robots can be mounted on walls, ceilings, rail tracks and shelves as well as firmly mounted to the floor. They can also be programmed to perform their tasks in confined places, thereby saving valuable floor space. natural pairing and the combination has resulted in making robotic operations leaner than ever before. Vision systems

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are commonly used to allow robots to vary their motion targets based on vision generated guidance information.

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Operations that required making visual distinctions and decisions (such as racking/ un-racking of parts, part picking from bins, and part inspections) were once exclusively handled by human operators. By combining robotics with vision guided systems, these same tasks can be performed by robots with higher consistency, accuracy, repeatability and speed. Vision-equipped robots can also reduce imperfections and scrap material in finishing operations such as routering, grinding, and sealing—contributing solidly to lean manufacturing. In the inspection arena, robots are utilised heavily in Flexible Measurement Systems (FMS). Robots mounted with vision cameras can collect information from multiple locations, dramatically reducing the number of vision cameras and fixtures required to inspect parts. Using vision-equipped robotics, lean manufacturing environments can be significantly improved, especially in areas where the movement, flexibility and simple decision-making of the human operator was once required. Cooperative Applications and Coordinated Motion (Flexibility, Speed and Accuracy) The latest robotics trend gaining acceptance as a lean process is coordinated motion. In this system, two or more robots are controlled by a single controller. The controller allows for easy communication between robots to simultaneously perform coordinated operations on a single large part. Coordinating robot movements can significantly reduce the time wasted in the manufacturing process. Roof assembly in the automotive industry is now commonly performed with one robot firmly gripping the automobile roof, while other robots weld and assemble the roof to the main auto body. Robots are also used for part transfer between assembly stations instead of transfer equipment like lift and carry systems or shuttles. The automotive industry is just one example of how coordinated robotics can aid in lean manufacturing,

ROBOTICS

improving cycle times and reducing scrap waste. Custom-designed fixture tooling is required at almost all product manufacturing plants. If the assembly process allows for a slightly lower level of structural accuracy, robots can be used in place of hard tooling fixtures. Robots with docking end-effectors or ‘geo end-effectors’ allow for reduced tooling content and greater flexibility, while maintaining a significantly high degree of accuracy and strength. Robots and Cycle Time (Speed and Accuracy) Many food packaging applications are solved by an operator (or team of operators) manually picking and packaging the products. This adds costs, can be physically demanding, and may create the potential for product contamination. Often, fixed automation is used, but this can severely reduce the flexibility of the application. When product marketing develops a new product or a customer demands a new package size or type, the fixed automation is often too inflexible to cost effectively deal with the change. Robots have become a powerful tool in the automation of pick and place applications such as pancakes, sausages, muffins and many other packaged or pre-packaged foods. In major manufacturing assembly plants, there are often hundreds of robots performing material handling, machine tending, welding, finishing, painting and other assembly operations. Wasted robot motion can cause cycle time issues, creating bottlenecks and loss of production. Poor path planning can cause product quality issues that can lead to scrap parts. The cost of lost production is a major drain on overall corporate profitability. Ensuring that the cycle time for robotic workcells is optimised is very important to the lean manufacturing plan. Some of the common cycle time issues impacting lean manufacturing are: Lack of part inventory for robots

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causing delays in production Unsafe work conditions causing slow human operation in situations where robots and humans work in a cooperative environment Poor equipment design resulting in wasted repair efforts Bottlenecked stations causing part blocking or starvation at other stations Individual robots over cycle causing entire station to be over-cycle Wait times on other equipment causing robots to go over-cycle Poor processing resulting in work overload on robots, operators or machines Poor human–machine interface causing delays in manufacturing Poor software & controls engineering resulting in inefficient I/O and communication between equipment. Detailed planning of robotic operations prior to system integration can go a long way towards controlling equipment and labour costs.

WORKPLACE SAFETY AND ROBOTS Most manufacturing operations have a degree of human injury risk. One of the primary reasons to automate a process using robots is to improve workplace safety. High-risk tasks like unloading parts from a fastmoving press or working with molten metal are definitely not tasks suited for human operators. In these cases, robots are invaluable in lowering the risk of injury or death. An unsafe workplace leads to feardriven human inefficiency, lowered production rates, higher insurance & workmen’s compensation costs, and high employee turnover. Conversely, a safe workplace boosts morale, increases employee retention and lowers costs, which ultimately improves the bottom line. And again, robots can significantly elevate the nature of work by removing people from dull, dirty & dangerous tasks. Robots can make the work environment safer by performing

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functions that are unsafe for humans, but robots themselves can be unsafe. For example, if a robot cell is not guarded properly, operators may take longer to service the station because of fear of injury. Whenever robotics are used, the environment must be carefully analysed and proper protocols instituted to keep the workcell safe. If the employees do not feel safe, the robotics implementation will not be as lean as designed. Many applications require the strengths of both people and robots, but until recently, this could be very dangerous. Now, specialised software can allow robots and operators to collaborate much more closely without compromising on safety. This combines the flexibility of human interaction with the precision and handling capacity of robots to make applications lean, accurate and very safe to operators.

TIME TO EXPLORE ROBOTICS OPTIONS Robots, if used correctly, can enhance a lean manufacturing environment. Robots offer speed and accuracy that cannot be achieved with human labour. Robots can also reduce operating costs, reduce scrap—and are flexible for future changes. Few other manufacturing solutions can reduce waste as well as robots when designed into the system properly. Robotics’ capabilities have only increased with time, while costs have continued to fall. Major robot manufacturers are constantly upgrading their robots with increased payload capacity, greater accuracy, increased reach and range of motion, improved speed and acceleration, faster communication with external equipment, better safety features, and lower operational costs. If you have not explored incorporating robotics into your manufacturing environment lately, it is probably time to take another look! This article is an excerpt from the white paper ‘Ten Ways Robots Enhance Lean Manufacturing Environments’ by ABB.

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AUTOMATION SOLUTIONS

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The government has ambitious plans to increase renewable energy generation to about 55 GW by 2022. To achieve this, India will need to increase its existing windpower generation by 50%, double its existing small hydropower and biomass power installations, and scale up its solar-power generation by a factor of 20 to 01 1 101001010 0101

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RENEWABLE ENERGY IN INDIA

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high costs, unpredictable output fluctuations and outdated gridconnecting technology) have upheld the dominance of thermal power in addressing India’s growing energy needs.

1010 0101101100011100011100011110000111001 0 1 0 1 1 0 0 101011001001010 1 001111000 10100110101 011 100110011010

ndia has been witnessing rapid economic growth and associated infrastructural 010101010101 10101010110011001100110100101 0 1 01 10 0 1 & industrial 10 0 01 010 1010 0101010101010011001100110 development since the last few 01 010011010010101 1010 10 1 01 101 years. Primarily, thermal 0 energy (largely coal-based), 10101 01010100111000111000111000111 1 which accounts for over 1 010 0 0 10010 0 01 1010 65% of the energy/power 000111000111000 0 mix, caters to the nation’s power needs. Coal-based ultra-mega power projects —each with more than 4,000 MW of capacity —have been proposed to add nearly 1,00,000 MW of capacity to the nation’s power grid. This further affirms India’s preference for thermal power generation. However, this preference is proving

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Renewable energy offers tremendous potential. To harness the potential of this sector to the fullest, there is a need to build state-of-the-art infrastructure. This, in turn, will create demand for renewable power generation equipment and for automation & control systems. As a result, over the next 10 years, the automation and control systems industry will experience signiﬁcant growth. harmful to the environment, as coalbased generation causes pollution. It also puts substantial pressure on the supply chain of one of the primary fuels of the country—coal. Moreover, due to the associated challenges, especially with respect to logistics, environmental clearances and project financing, thermal power generation is proving increasingly unsustainable. There is an immediate need to address the burgeoning energy demand in a manner that is sustainable on a long-term basis as well as has minimal adverse environmental impact. Renewable energy has thus emerged as a viable alternative and is increasingly gaining prominence. In addition, the fact that India has massive untapped potential for the development of solar, wind, hydro (small) and biomass resources makes a compelling argument for this change.

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Since the power sector in India is largely government-driven, a strong impetus is required from the Central Government, along with all the stakeholders involved, to bring about a paradigm shift in India’s power generation. These efforts need to be buttressed by a robust policy framework that incorporates interests of all stakeholders, addresses challenges that need to be overcome and provides a fertile ground (for instance, via incentives) for the power industry to grow rapidly in tune with the government’s short and long-term goals. Over the past few years, the renewable sector (especially the wind sector) has benefitted from the various government incentives, greatly increasing its contribution to the country’s energy mix. However, presently, inherent problems associated with renewable power installations (including major restrains such as

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achieve the target solar power capacity under the Jawaharlal Nehru National Solar Mission (JNNSM). Progress of the Solar Energy Sector India has hitherto neglected its solar energy sector, except for off-grid usage for applications such as lighting and heating. This can be attributed to various reasons such as high capital costs, inefficiency, uncompetitive generation costs, lack of coordination between various ministries, regulators and other industry participants, as well as a lack of clarity regarding regulations & incentives. However, JNNSM, which envisions a capacity addition of around 20,000 MW of grid-connected capacity in three phases by 2022, has brought a defining set of targets to develop India’s solar sector. Therefore, it is heartening to note that India recently crossed the 1-GW capacity mark for grid-connected solar

AUTOMATION SOLUTIONS

(which is largely encouraged rapid However, despite several incentives generation. Looking ahead, we can say capacity addition). and favourable policies, major that the reducing price of solar cells/ Government Policies Favouring technological challenges persist. This panels and the success of the National Renewable Power Generation affects the efficacy of efforts to add Thermal Power Corporation (NTPC) With an aim to increase the overall capacity in order to supply good Vidyut Vyapar Nigam (NVVN) power-generation capacity of the quality power to the grid. Therefore, Programme will continue to spur country, the government is developing for India to efficiently harness growth of grid-connected solar power certain policies to encourage renewable power, measures such as in India. investments in the renewable energy efficient renewable energy generation, Role of Biomass and Small Hydro sector, as well as allay fears of potential modern transmission and distribution Power Plant in Meeting India’s investors with respect to Return on (T&D) systems and energy Energy Needs Investment (RoI) or profitability of management systems that analyse the Biomass power generation, largely these projects, which are typically energy situation and leverage existing bagasse-based and agro-residueaffected by high-capital costs and high resources to optimal use need to be based, has lower overall potential (an (and uncompetitive) production costs/ implemented. estimated 20 GW) due to the lack of unit. Some of these favourable policies The critical components that will scalability of such projects. However, in place, or proposed, are as follows: facilitate the achievement of these in rural and semi-urban areas suffering requirements are state-of-the-art from sporadic power supply, poor Renewable Purchase Obligation automation and control systems, connectivity and bad power quality, (RPO): Under the regulation, every consisting of Distributed Control biomass-based captive generation state will have to buy a certain Systems (DCS), Supervisory Control would be extremely useful in meeting percentage of their power through And Data Acquisition (SCADA), local needs. Small hydro power plants renewable sources. Human Machine Interface (HMI), also contribute to India’s energy mix Renewable Energy Certificate (REC) Programmable Logic Controllers by catering to the smaller energy Programme: This system allows (PLC), asset management solutions needs of a local populace. However, those states that do not have and intelligent field devices. grid-connectivity to such remote renewable energy infrastructure to areas hinders the development of this fulfil their RPO quotas by sector. The government, through purchasing RECs at market rates. AUTOMATION IN RENEWABLE ENERGY the Ministry of New and Renewable Clean Development Mechanism Renewable energy, which has immense Energy, which is in consultation (CDM): This mechanism allows untapped potential, has been an area with the Alternate Hydro of interest for utility Energy Center (AHEC), companies seeking to Over the past few years, the renewable sector (especially is creating guidelines for increase their renewable the wind sector) has beneﬁtted from the various government setting up small hydro generation incentives, greatly increasing its contribution to the country’s e n e r g y power installations. These capacities, while investing energy mix. technical guidelines, in intelligent automation coupled with easy financing and and control systems to optimise India to achieve emission reduction incentives, would help step up the generation, plant optimisation and as well as earn saleable Certified growth of this sector. control & process monitoring systems. Emission Reduction (CER) credits, Success of the Wind Energy Sector Along with efficiency improvements on each equivalent to one tonne of The wind sector has seen significant the generation side, there is a greater CO2 at market rates. capacity addition over the past decade need for efficiency improvements on Clean Energy Fund: This will be due to various government incentives, the T&D side. created by taxing coal at the rate of viz., tax holidays, duty concessions and Unlike developed economies `50/metric tonne. Its proceeds will accelerated depreciation, among others. such as those of Europe and the be used to finance/promote This has encouraged investments by US, India does not have state-ofrenewable energy infrastructure. global and Indian companies. However, the-art T&D infrastructure. Such State-level Policies: At the state this capacity addition has not led to a situation leads to high Aggregate level, preferential pricing policies a commensurate increase in actual Technical and Commercial (AT&C) and fixing of RPOs for Distribution power generation. The government is losses, exceeding 30% in certain states Companies (discoms) by State trying to rectify this by emphasising on (compared to a global average varying Electricity Regulatory Commissions Generation-Based Incentives (GBI), between 5% and 10%). Furthermore, (SERCs) will incentivise renewable rather than accelerated depreciation the lead time from the evolution of energy-based power generation.

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AUTOMATION SOLUTIONS

connectivity, facilitating automatic different phases of operation—start, a technology protocol or standard to data capture and remote connect/ normal, emergency and shutdown— actual usage is substantially higher disconnect features, among others. to seamlessly move from one phase than that of developed countries, to another. It also needs to be in which runs up to 10 years or Despite relatively slow progress, the accord with various external factors, more. The reasons for this lag are upcoming Puducherry smart-grid pilot such as costs and market demand, manifold, but effect is the same—a and other independent (by individual among others. Conventional forms crippling, inefficient system that state utilities) & planned [by SGTF of supervisory control systems (i.e., wreaks havoc on a developing nation’s and Ministry of Power (MoP)] projects SCADA) might be inadequate in growth plans. It is clear that a stop-gap are positive signs that indicate the handling wide variations in outputs, situation will not suffice here. advancement of smart grid adoption as sampling could be too slow. Similar Over the past few years, the in India. When fully realised, smart is the case with conventional batteries, introduction of the Restructured grids can be an effective solution to as they would be unable to operate Accelerated Power Development and cater to the changing pattern of efficiently due to frequent chargeReforms Programme (R-APDRP) and power generation, with increasing discharge cycles associated with smart grid programmes seek (with a contribution of distributed renewable renewable power generation. strong mandate from the government) generation to the grid power supply. Efficient Renewable Power to address these glaring inadequacies so In recognition of this, the Smart Utilisation through Smart Grid that the link between generation and Grid Task Force (SGTF) and India The upgrade of generation and consumption could be strengthened. Smart Grid Forum (ISGF) have each transmission infrastructure must be Furthermore, there are increasing dedicated a specific working group to investments in High deliberate on various aspects Smart grid technology, when integrated to the power grid, Voltage Direct Current of distributed renewable will enable real-time data management, analysis & control (HVDC) transmission power generation in the regarding power generation and T&D. projects and consistent country. focus on localised grid accompanied by a commensurate improvement projects that has created ADVANCING TOWARDS A BETTER revamp of the distribution set-up, as a a positive outlook for the T&D sector. FUTURE system is only as efficient as its weakest Key to the success of these efforts lies In order to efficiently harness link. Smart power infrastructure can in automation and control solutions. the massive potential afforded by largely change the supply-based setChallenging Automation and renewable sources of energy, significant up to a dynamic, demand-responsive Control Requirements investment in modern power (or pull-driven) system—known as a Apart from difficulties in addressing infrastructure would be required. Such ‘smart grid’. There are certain critical the challenges of conventional power a need will have a cascading effect components in creating a full-fledged generation and T&D, issues related on the rise in demand for renewable smart grid. Implementation of smart to the integration of often-distributed power-generation equipment (solar grid demands intelligent automation renewables-based power generation, panels, wind turbines, gasifiers and systems that can cope with vast data intensifies the overall problem. inverters, among others) and for and multiple sources of power. Fast Conventional automation and control automation & control systems, which and reliable communication flow concentrate on maintaining certain is the critical glue that will integrate is another prerequisite. Smart grid parameters within the specified limits these components to the national power technology, when integrated to the and include safety measures to account grid. Therefore, over the next decade, power grid, will enable real-time for occasionally wide fluctuations in the automation and control systems data management, analysis & control the same. However, unpredictable and industry will see significant growth in regarding power generation and T&D. fluctuating output of renewable power overall demand, as both customers & In India, efforts are currently (such as solar & wind) will make equipment suppliers strive to cater to focussed on enhancing the distribution the process of optimising efficiency, the exacting requirements for control, side of the smart grid by installing improving profitability and integrating flexibility and safety. This would go of an IT-enabled system for data with existing grid systems challenging. a long way towards realising a wellcapture and remote control that is Unlike conventional industrial equipped, advanced power sector. enabled (from the field level) by a control requirements, renewable feature-rich Advanced Metering energy control will need to constantly An insight by Industrial Automation and Infrastructure (AMI). This system will use multi-variable control. The control Process Control Practice, Frost & Sullivan, feature two-way (utility and consumer) system would need to integrate the South Asia & Middle East

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OPINIONS & MORE

endeavour to provide our customers the best customer service in terms of 24/7 available telephone hotlines, presence of our on-field engineers, technically capable sales force, and so on. Although Lutron has grown substantially over the past several decades, the company still maintains the feel and personal closeness of a smaller firm. To this day, we still operate under the guidance of the company’s five principles: take care of the customers; take care of the company; take care of people; innovate with high-quality products; and always deliver excellent value. At present, we offer more than 15,000 products to satisfy virtually any residential or commercial project.

CREDENTIALS

Today, Saving Energy is at the forefront of our

purchasing decisions “Given the increasing levels of awareness on the importance of conserving energy, more and more products are being designed today by companies in order to become energy efﬁcient,” says Dr S Pekka Hakkarainen, VP, Lutron Electronics Co Inc, during an interview with Arindam Ghosh. He also shares his thoughts on a variety of issues ranging from the importance of lighting systems & controls to the initiatives taken by the company towards developing energy-efﬁcient technologies, various technological improvements in manufacturing and the company’s expansion plans. Excerpts… USP OF LUTRON ELECTRONICS We do not really focus on our competitors for understanding how we fare as compared to them; rather, we focus on developing technologies that we believe will help our customers in the best possible way. User interface is one of the most important aspects of our product line, which means that the person who is operating the lighting system must be

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able to interact with the interface. We believe that our products must look good; they need to be user friendly as well as ergonomically designed. These are just some of the aspects we focus on. In addition, the ultimate goal and principle of our company are to take care of our customers in the best possible manner and provide them high-quality, reliable products. It is our

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Dr S Pekka Hakkarainen has an experience of over 20 years of working with Lutron Electronics. Pekka is currently serving as Chair of the Lighting Systems Division of the National Electrical Manufacturers Association (NEMA). He is a voting member of the ASHRAE 90.1 Committee. He also holds seven US patents.

MANY FIRSTS Joel Spira founded Lutron Electronics Company Inc in 1961, a little over 50 years ago. The company has many firsts to its credit and the list is very long. For instance, the company developed the world’s first ‘dimmer switch’, which was the world’s first solid-state electronic device to dim lights in homes, replacing bulky rheostats and auto-transformers that were inefficient and unattractive. Dimmer switch was also the world’s first commercially successful dimmer. In the early 1970s, we introduced America to a new style of architectural dimmer—the Nova Linear Slide. The rugged Nova dimmer, with its distinct linear slide control, was designed for demanding applications of up to 2,000 Watts. The product was so

OPINIONS & MORE

widely accepted that the company had to expand the family of products to include dimmers for all light sources, plus switches and fan controls. Today, Nova is one of the most recognised and utilised products in the lighting control market. The first complete home lighting control system was introduced in 1990, which offered utmost convenience to large homes and estates. In 2007, we introduced Vierti single-touch dimmer—representing the very latest in innovation and cutting-edge design. This dimmer lets users set the perfect light level with just a single touch or slide of the finger. The Vierti dimmer is designed to complement both residential & commercial spaces and is offered with multiple LED & wall plate colours. To this day, we remain the only company that provides an integrated solution for controlling both natural daylight as well as electrical lighting.

architecture. Therefore, there is light only when you need it—thus saving energy. LED lighting control: The use of highly efficient LED lighting for general and accent lighting is on the rise. Further, we also have products based on sensing technologies that provide light only when and where it is required. They are perfect for certain areas of a facility that require illumination only when someone is present. Lutron customers save 9 billion kWh of energy each year, which is as much energy as 2,000

IMPORTANT ENERGY-EFFICIENT TECHNOLOGIES

UP CLOSE & PERSONAL

Given the increasing levels of awareness on the importance of conserving energy, more and more products are being designed today by companies in order to become energy efficient. From the cars we drive to the appliances we use, saving energy is at the forefront of our purchasing decisions. In addition, in office buildings, which use more electricity for lighting than any other building system, controlled lighting is usually the easiest and the most viable way to manage your energy costs while enhancing your space at the same time. Our company is committed to helping customers find new ways to save energy in the best possible manner. Some of the major energysaving solutions we offer include: Automated lighting: Our astronomic time clock turns lights on at sunset and off at sunrise, or at a preset time. Lights can be controlled to create safe pathways and automate dramatic lighting of landscaping &

Your passion… Learning is my biggest passion. Book that inspired you the most… At present, I am reading a book called ‘Kill the Company’ by Lisa Bodell. The books talks about innovations & development. It also talks about how to get rid of business practices that harm the company. It is very interesting and I am wondering if we can apply some of its thoughts in our company. Message to competitors As we are working to develop solutions that ensure energy savings for our customers, it is critical for us as an industry, to further educate the masses on the benefits of implementing these technologies. This will play an important role in not only the growth of our business, but will also, in the process, lead to a greener tomorrow. Collectively, I believe we have an opportunity as well as a responsibility, which will make our industry sustainable.

windmills produce in one year. The energy is enough to light 4.5 million homes for a year. Lutron has also invested 10% of its annual revenue into research and development for developing newer technologies and solutions.

KEY CONSIDERATIONS For developing a new product, we look at the market and try & access the requirement levels of the product. We also need to see whether the product will be quickly adopted in the market. However, in some cases, if we feel that the product is necessary for the growth of the market, we may develop it. Moreover, from a technology perspective, we look at the maturity level of the technology in terms of its commercialisation. One good example of this is the wireless technology, which we developed 20 years ago. There were many concerns that it might not work on a large scale, but fortunately the technology worked well. It enabled us to stay in the residential segment for a long time. Further, our experience in wireless technology helped us to generate business in the commercial segment as well, especially during the period of economic downturn few years ago, when various economies turned backwards and the economic activities slowed down.

DEMAND TRENDS With respect to commercial buildings, office buildings have a very high requirement for lighting control because of rising awareness of energy efficiency. The drivers for such a high level of awareness among the building owners for installing such lighting control system comes from various green-building standards that are being followed across various parts of the world. The government and the industry are big owners of office buildings. They have set certain standards for energy efficiency, which has led to a strong level of demand

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OPINIONS & MORE

for lighting control and systems. The other segment that has a high demand for such solutions is that of educational institutions and schools. In an effort to reduce their operating cost, schools and other educational institutes have installed lighting control systems at their facility. Here, the main driver is energy cost that has promoted the demand for these products. Further, there is a huge demand in the hospitality and retail industries. Here, the ability to personally control the illumination levels in a hotel guestroom is the key to enhance guest experience. Adopting such technologies also gives them huge scope to brand themselves in the market as being energy efficient, which, in the process, further promotes the use of such solutions.

We believe that our products must look good; they need to be user friendly as well as ergonomically designed. efficient solutions. The country is also adopting various initiatives to move in this direction. With the rising level of awareness on implementing energyefficient solutions, the Indian market offers us huge scope for growth and expansion of our business. In terms of the initiatives, the government can play an important role by bringing in various policy initiatives, such as tax initiatives, subsidies, or, maybe, mandatory use of such technologies, and other such initiatives. These set of reforms can play an important role in encouraging the implementation of these kinds of equipment.

New York, the US. The company decided to bring in all the offices under a single building. They came to us and implemented our solutions. Our lighting management system delivered an absolutely over-the-top performance. It resulted in a huge level of energy savings. The lighting energy savings achieved by The New York Times Building are primarily from the following strategies: 10% daylight harvesting; 2% scheduling system for turning lights off during certain times of the day; 30% occupancy sensing and 58% light-level tuning for each space. This project also led to the development of our state-of-the-art solution for green buildings.

EXPANSION PLANS

YOUR PERCEPTION OF THE INDIAN MARKET

PROJECT CLOSEST TO YOUR HEART

We are making investments in various economies, like India, Brazil and Russia, for the growth of our business.

I have seen a huge interest in the country to become a leader in energy-

The project closest to my heart remains The New York Times Building in

arindam.ghosh@network18publishing.com

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TECHNOLOGY ACQUISITION AND DEVELOPMENT FUND

Laying a Strong

Foundation for

NIMZs

The government is planning to set up Technology Acquisition and Development Fund (TADF) to support the development of the proposed National Investment and Manufacturing Zones (NIMZs) under the National Manufacturing Policy (NMP). The fund will be established for acquiring appropriate technologies, including eco-friendly technologies, creating a patent pool, and developing the domestic manufacturing of equipment used to control pollution and reduce energy consumption. The fund will also provide 10% subsidy on the capital investment. With such promising prospects, TADF is set to act as a catalyst in increasing the share of the manufacturing sector in the GDP to at least 25% by 2022 from the present 16% under NMP.

ARINDAM GHOSH

aking a strong step towards rolling out the National Manufacturing Policy (NMP) in India, the government is planning to set up a Technology Acquisition and Development Fund (TADF). The policy initiative will support the development of the proposed National Investment and Manufacturing Zones (NIMZs). These specific regions in the country will be mega-industrial zones having world-class supporting infrastructure. The government is making various efforts to bring in a host of incentives to promote the development of these zones. The move also holds significance is the current background where the country’s exports have fallen due to lower levels of demand, especially from countries such as Europe and the US, which are India’s major markets. This, in turn, has

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hurt the productivity of the country’s manufacturing sector. TADF will be established for acquiring appropriate technologies, including environment-friendly technologies; creating a patent pool; and developing the domestic manufacturing of equipment used for controlling pollution and reducing energy consumption. Commenting on how critical it is to set up this fund for promoting the productivity of the manufacturing sector, Amit Kapur, Director, Everest Group, says, “The government’s decision to establish TADF will play an important role in the development of Micro, Small and Medium Enterprises (MSMEs). It helps them in accessing designs, patents, processes and technologies. The fund will also help in the acquisition of clean technology.” “Over the years, various policy

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initiatives and economic reforms have enabled India to emerge as one of the fastest growing economies in the world. However, the performance of India’s manufacturing sector causes concern, particularly when compared to the manufacturing sectors of other countries in similar stages of development,” Kapur continues. “The increasing gap in both the sectoral share of manufacturing and the productivity of the manufacturing sector in India, when compared with such countries, including China, indicates that the country has not been able to fully leverage the opportunities provided by the dynamics of globalisation,” Kapur adds.

MAJOR CHALLENGES The government has initially chalked out 10 industries, including pharmaceuticals, IT hardware, auto components, defence, aerospace and

TECHNOLOGY ACQUISITION AND DEVELOPMENT FUND

the modalities of the biotechnology, which The government’s decision to establish TADF will scheme. He says, “Such will be taken up in play an important role in the development of a fund could, therefore, the initial phase. The MSMEs. It helps them in accessing designs, provide for investment, government is planning patents, processes and technologies. The fund will also help in the acquisition of clean technology. and, if suitably to provide up to 15% Amit Kapur, Director, Everest Group implemented, would give cost of purchasing plant manufacturing a boost, as and machinery for the well as the capability thereof.” agency. It should purchase Intellectual project. Alternatively, interest-free Property (IP) rights to inventions from loan will be provided for a period of patent holders. Any company, which five years and will cover 50% of the MANUFACTURING SECTOR UNDER wants to use the IP to produce or acquisition. However, as part of the HEAVY POLICY ATTENTION develop products, should be able to challenge that a company may face NMP is one of the most ambitious seek a licence from the pool against under the scheme on certain occasions, policy reforms of India, which the payment of royalties. The company a company may be unable to access aims at increasing the share of the may then produce the product for use a patented green technology in order manufacturing sector in the GDP to in specified geographical areas subject to reduce its carbon footprint. It can 25% by 2020 from the present level to meeting agreed quality standards. happen because of its inability to of 16%, as well as create 100 million TADF should reserve the right to obtain a voluntary licence from the jobs during the same period. The licence more than one company for a patent holder. Such a scenario could government is actively working in this particular product.” arise because of two reasons; firstly, direction. In a big push to implement According to Kapur, if a proper the cost of obtaining such a voluntary this scheme, the government of India mechanism was developed under licence, and secondly, the patent has recently formed the Manufacturing TADF for timely release of funds and holder could be unwilling to part with Industry Promotion Board (MIPB) long-term soft loans, it would play an the licence. In order to tackle the under the Chairmanship of the Union important role in further strengthening scenario, reasonable royalty will be Minister for Commerce and Industry, paid to the patent holder under the Anand Sharma. The 13-member policy. Elaborating further, Kapur board will conduct a periodic review TADF COMMITTEE points out, “There are resources for on the implementation of NMP acquisition of machinery and working across the country. It will carry out A Green Manufacturing capital. However, there is no fund a thorough analysis of the stateCommittee (GMAC) for matters available for technology acquisition as wise and sector-wise performance pertaining to the Policy on of now. Unless we create a facility like of the manufacturing sector. The Technology Acquisition and Development Fund (TADF) under this, our industry will be left behind.” panel further aims to develop a the National Manufacturing Policy policy framework for creating better has also been notiﬁed. co-ordination among various agencies STEPS REQUIRED The Committee will prescribe of the state and central governments In the initial stage, there will be objective criteria for categorising in order to ensure faster and easier maximum funding of `3 crore. There a technology as ‘clean and green’. clearances & approvals on issues will also be slabs for funding, which The criteria will be consistent with related to manufacturing. would be given for each technology the objective of the National acquisition and development fund Over a period of time, the Action Plan on Climate Change proposal. The scheme is very critical manufacturing sector has increasingly and the strategy for inclusive for companies looking to gain a been receiving attention from the sustainable development. technological and a sustainable edge in government, and initiatives like The Committee Chaired by the market. Commenting on the steps TADF and MIPB highlight the intent Secretary Industry will also constitute a panel of experts/ that can be followed for making the of the government to make the sector agencies/environment auditors scheme a success in the country, Kapur competitive and improve the overall for the purpose of third-party says, “The focus of the industrial industrial output in the country. By certiﬁcation. This Committee will policy is not to ‘pick winners’, but to taking such measures, the sector can operate and review the create an ecosystem in which more achieve the targeted contribution of Technology Acquisition and winners emerge. And, as they emerge, 25% to the country’s GDP in a decade, Development Fund and will the ecosystem enables them to become as prescribed by NMP. formulate guidelines for the stronger. TADF should function as an operation of the fund. autonomous patent pool and licencing arindam.ghosh@network18publishing.com

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LEADERSHIP MANTRA

Fo owers make

eaders

Leaders have the ability to mobilise the masses; but it is the followers that make a leader. Leaders would not be able to accomplish their goals without a set of followers who work towards ensuring that these goals are met. If leaders ignite the spark, followers act as the catalyst that keeps the reaction alive. f you ever find an occasion to amble into a bookshop, say, while waiting at the airport for a flight, you would definitely come across at least half a dozen books on leadership from all over the world. All these books are based on the experiences of great leaders of our time—right from Mahatma Gandhi to Jack Welch and Steve Jobs. Every time I see these books, I never fail to be struck by a strange anomaly. If there are so many books on being an able leader, how come there are none on being an able follower? The dictionary defines a leader as: A person or thing that leads. A guiding or directing head, as of an army, movement, or political group. It is obvious from these definitions that the leader derives his/her identity from the group or persons that follow him. When we come to industry circles, most management books love to depict leaders as someone who brought out order from chaos or threw brilliant light and helped an organisation find the right path. However, a closer analysis of this reveals that this is not really true in a majority of cases. Leaders often form rallying points for intelligent, dedicated, hardworking and committed people who then jointly forge a way to success for the organisation as a whole. In most cases, it is also seen that these followers continue the work and keep moving the organisation to greater heights long after the leader is gone. These

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facts make it difficult to ignore the importance of the team that the leader led or the followers that the leader had.

FOLLOWERS REINFORCE LEADER’S FAITH History is replete with such followers without which leaders would possibly have accomplished only a part of what they did. These followers are well known to you and me; but have they been accorded the place they deserve? One of the greatest leaders in human history is undoubtedly Mahatma Gandhi—a man we revere as the one who always stood up to his convictions. However, how many of us have really looked at the role of Kasturba Gandhi in all this? This lady was married to a man she did not know at a tender age—a lady who followed this man’s convictions wholeheartedly at great personal discomfort. Could Gandhiji accomplish all that he did without the support of his soulmate, Kasturba? Odysseus is another great example of an able follower. He was always the lieutenant and never the leader; yet, the great epic cannot be complete without him. Victory could not have been a reality for the Greeks in the Trojan war without his support. In Indian mythology, Arjuna is a classic example of a great follower. A demi-God himself, Arjuna is completely loyal to Krishna & follows him with utmost faith & unflinching

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commitment, thus acquiring greatness. Leaders have great faith in themselves, their goals & their ability to achieve it. Followers put their faith in the leader & display commitment to the cause espoused by him. This is a great act of courage. To believe in oneself needs conviction, but to believe in another & commit to him needs courage.

AT THE INDUSTRIAL END… Coming to industries, a CEO would have a vision where he wants the organisation to be. He then draws up a broad road map to execute or achieve the goals set. All leaders have huge tasks to accomplish, less time to accomplish these in and generally very less resources to work with. Against this backdrop is the band of committed followers who create a reality of the vision that their leader has. Most of the heartaches at the operating level, resistance to change and the negativism to any thing new are faced mostly by this group. Thus, in my opinion, there are basically three categories of people in any organisation: The leader The band of dedicated followers The general populace who will go where they are asked to and will stop there unless pushed again. While the importance of leadership cannot be ignored, I firmly believe that leaders cannot execute successfully without the second

LEADERSHIP MANTRA

group. This second group forms the catalyst for change

as it cuts through various operational & organisational barriers and forms a bridge between leadership & the rest of the organisation. These people are the first to attempt converting the leader’s vision into actions. They are the ones who work out the details over the broad road map given. They also anticipate the pitfalls and guide the teams over difficult periods. These followers are not mere followers or people of blind faith. These are intelligent men who recognise early the mettle of the leader and the truth of what he says and believes in. However, what really makes them men of respect is that they decide to take the difficult road set by the

leader and make sure that their followers follow suit. Like the leader, they

too display the same degree of commitment—courage against adversities and desire to make things happen. This, to me, is worthy of recognition, worthy of respect.

IMPORTANT TO FIND FOLLOWERS Great leaders bring about changes & devise new ways of doing things, while great followers ensure continuity of both long after the leader is gone. We still talk of the ‘GE Way’ & the ‘Toyota Production System’. I am sure that these would not be alive today had a dedicated band of followers not institutionalised what the leaders envisaged. Behind each dedicated leader, is a group of committed followers who are as important to the organisation as the leader is.

It is important to find dedicated followers within the organisation, who will reach out to a vast number of people in the organisation & mobilise them towards the path of change to the extent that they start believing that by taking the difficult road ahead change IS possible. This just cannot be accomplished by the leader alone or in isolation. It is just beyond comprehension that the leader talks to each person or reaches out to say 50% of the organisation and spends enough time convincing them about change. If leaders ignite the spark, then followers are the catalyst that keeps the reaction alive. Let us remember that behind every dedicated leader, stands a dedicated team of talented followers who convert words to actions and goals to reality. Hence, do not forget the follower! AK Chari, GM – Supply Chain, Ferromatik Milacron India, Ahmedabad Email: ArunKumar_Chari@milacron.com

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OPINIONS & MORE

FDI IN MINING As India is a mineral-rich country, it has considerable scope for augmenting its resource position by further exploring known deposits & discovering new ones and adopting advanced technologies & modern mining methods. The Government of India has been consistently opening up private sector participation in the mining sector to infuse funds, technology and managerial expertise. FDI Policy in the mining sector was further liberalised in 1997, opening up an ‘automatic approval’ route for investments involving foreign equity participation of up to 50% in mining projects and up to 74% in services incidental to mining. FDI cap for exploring and mining diamonds & precious stones has been increased to 100% under the automatic route with effect from early 2006. With this, the FDI in the mining sector for all nonatomic and non-fuel minerals have now been fully opened up to 100% through the automatic route. Table 1 shows the FDI inflows into the mining sector during the last few years. However, only those companies that are incorporated in India can apply for FDI through equity participation.

FDI in mining is increasing the growth of domestic end-user segments in India “The Government of India has been consistently opening up private sector participation in the mining sector to infuse funds, technology and managerial expertise,” says, Venkatesan Subramanian, Director – Metals & Minerals Practice, South Asia, Middle East and North Africa, Frost & Sullivan, during a tête-à-tête with Prateek Sur. Subramanian shares his insights on FDI in mining, safety & environmental issues in mining as well as the global and Indian standards of mining equipment. Excerpts… Companies are required to apply to the concerned state governments, who are the owners of minerals in their respective territorial jurisdictions, for mineral concessions. Though this causes procedural delays in obtaining mining licences, FDI in mining sector

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increases the growth of domestic enduser segments viz., iron, steel, power and other such industries in India.

SAFETY PROCEDURES IN THE MINING SECTOR Safety has long been a concern in the

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mining sector, especially in sub-surface mining. Some standard mining safety precautions followed by the industry are as follows: Proper Ventilation: During mineral excavation, miners may come across many toxic substances. Therefore,

OPINIONS & MORE

adequate ventilation throughout a mine is crucial. In addition, miners are also provided with face protection masks that include a respirator to protect their respiratory organs. The mines are ventilated with the help of one or more mine fans, usually located above ground. Mine ventilation systems are regularly checked, and air quality is monitored to check for toxic gases. Usage of Reinforcements: All freshly mined areas are meticulously checked to protect miners from cave-ins. Reinforcements are also checked on a regular basis. Personal Safety: Apart from masks, miners also wear heavy clothing, helmet and boots to protect their bodies. Sharp or projecting objects are removed or clearly labelled so that miners do not hurt themselves. Mines also use extensive lighting systems for visibility. Holes and shafts are covered over or brightly labelled so that the gear or miners do not fall. Other potential sources of danger, such as electric wires, are neatly covered and labelled. Proper Individual and Location Mapping: Miners sign in & sign out when they report for work. They also make each other aware of their positions inside the mine. Most mines have a route map & evacuation plan in case of any emergency, and miners are provided with the details of the plan. Usage of Electronic Devices: Nowadays, miners use technologies and modern communication systems, safety light, automated loaders, remotely operated rock breakers, etc., during mining.

EFFECTS OF MINING ON THE ENVIRONMENT AND THEIR SOLUTIONS Despite its economic importance, the harmful effects of mining on the environment are a pressing issue. The environmental impact of mining includes erosion, formation of sinkholes, loss of biodiversity,

deforestation and Table 1: FDI Inflows into the Mining Sector contamination of soil, Year FDI (` Crore) groundwater & surface 2008–09 161.09 water by chemicals from 2009–10 829.92 2010–11 357.42 mining processes. Besides 2011–12 (April 2011 to May 2012) 436.61 creating environmental Source: Department of Industrial Policy & Promotion, Government of India damage, the contamination resulting from the leakage of chemicals also affects the health INDIA’S MINING EQUIPMENT VIS-À-VIS of the local population. In areas of GLOBAL COUNTERPARTS wilderness, mining may destruct and With a large production capacity base disturb ecosystems & habitats, and in and the use of a vast product line, areas of farming, it disturbs or destroys India is among the few developing productive grazing and croplands. countries that are self-reliant in mining Following are some of the methods equipment sector. However, India has to reduce the environmental impacts only a few companies, mainly medium of mining: and large, in the organised sector that manufacture mining equipment. The Increase the efficiency of technology barriers are high, especially manufacturing processes with respect to mining equipment. Use recycled materials; for example, Therefore, the role of SMEs in the use recycled aluminium instead of Indian mining sector is restricted to bauxite the manufacture of components and Legislation and regulations to some sub-assemblies. reduce environmental impacts; for Till the 1980s, the domestic example, the New Mining Policy requirements of mining equipment will reduce environmental impacts were met by imports. However now, Clean up abandoned mine sites. with the opening up of the economy, the sector is witnessing many changes. CREDENTIALS Most of the global technology leaders, such as Caterpillar, Hitachi & Volvo, Venkatesan Subramanian obtained are present in India as joint venture his BSc (Chemistry) degree from companies or have set up their own Vivekananda College and BE manufacturing facilities or marketing (Metallurgical Engineering) degree from the Indian Institute of Metals. companies. He has 31 years of work experience of The sector has made substantial in both ferrous and non-ferrous metal investments in the recent past for industries. Subramanian has worked setting up manufacturing bases, despite in leading domestic and foreign small volumes and uneconomic scales companies and has worked in several of production. Due to the increasing areas of the mining sector such as volume of mine activities, the mining production & manufacturing, quality equipment sector is poised to grow control & inspection, marketing & in the medium to long term. When sales, project development and compared to global mining equipment general management. He has sector, the growth in India would previously headed the Projects & be high. However, when compared Business Development Division for Metals & Minerals at Oman Oil – to other mining economies like Takamul Investments, Muscat. Australia & Chile, the usage of Presently, he is working in the ﬁeld of advanced technologies in mining market consulting and is heading the processes & automation level is Metals & Minerals Practice Division, relatively low in India.

South Asia, Middle East and North Africa, Frost & Sullivan.

prateek.sur@network18publishing.com

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PAINTS & POLISHES SELECTION GUIDE

Steps to Enhance Durability

Selecting quality paints & polishes for machinery and components is emerging as an important point of discussion among companies who are trying to improve their manufacturing processes to remain competitive in the market. Here are some ways to help companies choose quality paints & polishes and enhance their productivity & efďŹ ciency. ARINDAM GHOSH

ith an aim to tackle the rising level of competition in the market and increase the productivity of the manufacturing process, choosing appropriate paints & polishes is emerging as an important parameter. Over a period of time, the Indian market for industrial paints has grown immensely. In order to make the market more competitive, paints and polishes are also being developed today to cater to certain specific applications. Here are some of the tips/pointers that, if followed, may help companies in the appropriate selection of paints and polishes.

SELECT SOLUTIONS FOR SPECIFIC APPLICATION Today, many manufacturing companies of paints and polishes are introducing specific solutions for specific applications in the market. Opting for such products will strongly enhance the productivity of the production process. Some of these solutions are not only highly specialised in their application, but are also easy to use, economical and safe to handle. Further, quality paints for all types of industrial requirements are available these days.

QUALITY OF THE SOLUTION Quality of the solution is very critical

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to bring in improvement in the manufacturing processes. However, to bring in quality solutions in their facilities, companies need to be flexible and should be prepared to spend a little more to get better quality products from the market. If the quality of the product is high, it will help in obtaining better results from the product. With the entry of the many players and cut-throat competition in the market, the user industry now has a number of options.

company save energy, but will also give it scope to create a niche for itself in the market. More importantly, the company will be able to sustain itself and compete in the market.

LIFE CYCLE OF THE PRODUCT Life cycle of the product is another critical aspect that the user industry should look into. Higher the life cycle of the product, higher is the return for the user industry. Though the initial cost of product may be high, it ensures profitability over a period of time.

NATURE AND COLOUR OF PAINT The paint should be suitable to adapt to any kind of environment. Some industries may need heat-resistant paints. Wrong selection of paint can cause severe damages and thus the selection should be done carefully. Further, the paint colour needs to be chosen keeping in mind numerous factors; for instance, where it will be applied, the environment, etc. In many cases, the machines or the production process may go through a lot of wear and tear.

ELEMENT OF AESTHETICS With the improvement in technology for manufacturing, industrial paints has now become highly specialised in application. However, if the paint offers quality in terms of its look and feel, it can come in handy for paint manufacturers. Though aesthetics does not have much importance for industrial paints, it can certainly give the vendor or the supplier a competitive edge.

AVAILABILITY OF THE SOLUTION ENERGY EFFICIENCY Given the rising levels of awareness on the importance of conserving energy, today, more and more products are being designed by companies to be energy efficient. Selecting these products will not only help the

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Availability of the product is very important. If a product is not regularly available in the market, it may bring in high levels of losses for the supplier and may harm the user industry. arindam.ghosh@network18publishing.com

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250+ participants | 17,000+ business visitors expected | 10,000+ products on display Business transactions worth ` 85 crore expected | Spread over 3500 sq mtr Showcasing more than 30 diverse industry categories.

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Exhibitor Profile

NEW LAUNCHES This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 198 to find it quickly

ANGLE MEASURING INSTRUMENT

ngle measuring instrument has a completely new sensor cell in the reliable ‘Seal-Tec’ technology for excellent performance even in difficult environmental conditions. The zero adjustment can be easily done while using this instrument. The measurements calculated are absolute and relative. It provides a measuring capacity of +/- 45 degree. Four precisely machined exterior reference surfaces assure accuracy and repeatability of measurements in any quadrant. Application areas include measurement of machine tool elements, aerospace industry, angle checking etc. The instrument can be used for applications where angle/inclination/slope is to be measured. Bombay Tools Supplying Agency Mumbai, Maharashtra Tel: 022-23426495, 23421326 Fax: 022-23401933 Email: info@bombaytools.com Website: www.bombaytools.com

FIRE SLIDING DOOR

ire rated sliding door is available in single and double leaf door with a maximum size of 8500 x 6000 mm and fire resistant to DIN 4102. The door is ideal for large wall openings and in scenario where headroom is limited. Frames can butt up to a ceiling or fix directly to overhead lintels. Braking devices and automatic control systems can keep doors permanently open and close them in emergency. Personnel access doors and wicket doors can be supplied without a bottom sill allowing them to be used when the ‘parent’ door remains closed. Fire resistant glazing can be fitted to access doors and sliding panels. Fire rated resistance is 2 - 4 hours. The door is compliant with BS 476 part

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22/UL/FM/REI 120. Gandhi Automations Pvt Ltd Mumbai, Maharashtra Tel: 022- 66720200, 300 Email: sales@geapl.co.in Website: www.geapl.co.in

BEARING

he bearing satisfies running accuracy class P4 and angular contact ball bearing standard with a phenolic cage. Two type of ball bearings are available; angular contact ball bearing and double row cylindrical roller ball bearing. The series of angular contact ball bearings are: universal matched with light preload, universal matched with medium preload and universal matched with heavy preload. Double row cylindrical roller ball bearings series are available in metric and NNU version. .

Austin Engineering Company Ltd Junagadh, Gujarat Tel: 02873 - 252223, 252224 Email: sales@aecbearings.com Website: www.aec-bearings.com

BENCH GRINDER

ench grinder with built in dust collector is specially designed for collecting dust generated during the grinding process. It is mounted on a rigid steel frame and has high fi ltering efficiency, enabling it to grasp even the fi nest dust particles. It has features like low power consumption and low noise level. Cotton fi ltering sleeves provide total security against infl ammation. It has a

NEW LAUNCHES

1.0 HP, 3 phase 2800 RPM grinding motor, 3 phase dust collector motor and is fitted with a manual shaker. The machine has dimensions of 775 x 800 x 1050 mm..

Prem Brothers New Delhi Tel: 011-28117456, 28117464, 45595068 Email: powermaster59@gmail.com Website: www.powermaster-india.com

CAM FOLLOWER

tud type cam follower is available in standard as well as eccentric stud, cage/ needle guided, cylindrical/crowned outer race, grease fi lled and ready to use. Holes for grease nipple and plug fitting are provided. Th is can be used as full complement bearing and can take heavier loads at lower speeds. Application area includes all medium and heavy industries. The cam follower is grease-lubricated, maintenance-free, and includes slight gap adjustment by eccentric.

NMTG Mechtrans Techniques Pvt Ltd Ahmedabad, Gujarat Tel: 079-22821527, 22817688 Fax: 079-22820214. Email: nmtg@nmtgindia.com Website: www.nmtgindia.com

DIAMOND DISC

iamond discs use a process by which diamond abrasives are chemically fused on top of a metal base. The construction provides highly exposed, ready to cut diamond edges at the contact surface to either grind or hack. With reduced friction at the cutting edge and a well balanced construction, the power tool mounted breaks down very less and completes the work much faster. It can be fitted on any brand of portable grinder. It is available in 100 mm (4”) diameter with 20 mm bore, 115 mm (4 ½”) and 125 mm (5”) with 22.3 mm bore. The same discs can be used both for grinding and hacking applications.

Wendt (India) Ltd Hosur, Tamil Nadu Tel: 04344 - 276851, 276852 Fax: 04344- 405620 Email: deepaks@wendtindia.com Website: www.wendtindia.com N O V E M B E R 2 0 1 2 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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NEW LAUNCHES

FIBER LASER

iber laser combines all the advantages of a system with an electronic source, fiber-optic beam delivery and high dynamics provided by the original â&#x20AC;&#x2DC;compassâ&#x20AC;&#x2122; structure for enhanced performance. The compass is a movable articulation made possible by the absence of a defi ned optical path, which allows the cutting head to move over a distance of 170 mm on the XY plane, with dynamics up to 5g. The compass is driven by a pair of rotary motors which represent the heart of the mechanical solution. It offers dynamics similar to those of linear motors and yet consumes less than 1 KW of power during operation. It does not need dedicated cooling systems or optical scales.

Salvagnini Machinery India Pvt Ltd Bengaluru, Karnataka Tel: 09913815775 Email: riddhish.jalnapurkar@salvagninigroup.com Website: www.salvagninigroup.com

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FORCE FEED LUBRICATOR

igh pressure and low pressure lubricator up to 24 feed pumps are available. Each feed pump produces discharge up to 0.30 CC/ stroke, working pressure up to 1000 kg/Cm 2 alongwith different type of gear reduction from 1:2 to 1:400 with ratchet drive, handle drive. These lubricator are ideal for air and gas compressor, reciprocating plunger pumps, rubber and plastic machinery and similar other industries.

Zenith Hydromatic Ahmedabad, Gujarat Tel: 079 - 22812945 Email: zenith_amrut@yahoo.com Website : zenithhydromatic.tradeindia.com

GEARED HEAD LATHE MACHINE

eared head lathe machine has rigid construction and sufficient power for higher metal removal rate. Th is machine has closed grained casting and is well ribbed to

NEW LAUNCHES

minimise vibration and distortion. Main bed is hardened and precisely grounded. The headstock is made up of closed grained cast iron with appropriate wall thickness. Main spindle is made up of alloy steel with case hardening and grinding. These gears are made from 20MnCr5 material which is hardened and grounded. Spindle is mounted on taper roller bearing. Spindle speed has a range from 60 - 1100 rpm with 8 speeds. They also have MT4 in spindle nose. Machine and practical tests are done as per IS: 1878 (Part-I).

Vinit Engimech Pvt Ltd Rajkot, Gujarat Tel: 0281-2312091, 2311734 Fax: 0281- 2311935 Email: vinit@balajilathe.com Website: www.balajilathe.com

POWER OPERATED HYDRAULIC PRESS

ower operated hydraulic press ranges from 15 tonnes to 300 tonnes capacity in mild steel robust construction. The crown, column and bottom are solid without bend and are welded.

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NEW LAUNCHES

The table is vertically operated by worm winch gearbox and rests on load pins placed in holes and column at desired height. An option to operate bed by bed lifting attachment electrically is provided. Rollers are also provided with the bed for easy handling of heavy jobs. The cylinder is made from honed tube and hard chrome plated ram is made from mild steel, operated by double acting cylinder. Good quality seals assure long working life. The ram is provided with replaceable socket to facilitate attachment of dies and tools on customerâ&#x20AC;&#x2122;s request. The press is equipped with high pressure hydraulic pump, D.C. valve, pressure relief valve etc. Pressure can be regulated by pressure control valve. The press is operated by hand lever operated direction control valve, with an option of panel board/push button operated and foot operated.

Dowel Engineering Works Rajkot, Gujarat Tel: 0281-2362465, 2369153 Email: dowel@thedowel.com Website: www.thedowel.com

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PAINTS, COATINGS & POLISHES

POLISHING FILMS

olishing fi lms comes in optimum quality and are high in strength and durability. Polishing fi lms are used to polish extremely hard materials easily and precisely. They are available in different range, size and shape such as diamond, silicon carbide, aluminium oxide coatings etc. Polishing fi lms features applied and cautiously opted diamond powder, newly developed binder and coating procedure, high bond strength and durability. It polishes extremely hard materials smoothly. Polishing fi lms can be applied in metallic mould, alloy, super-hard-metals, ceramics, sapphire, ferrite, fiber optic connector and glass. The fi lms have the dimensions of base fi lm 75Âľm, PET fi lm sheet size 228 mm x 280 mm (10 Sheets / Set), disk size of +/-110 mm, +/-127 mm (10,50 Sheets / Set).

Mipox India Bangaluru, Karnataka Tel: 080-22260060, 09972053377 Fax: 080-22260060

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Email: rag-rao@mipox.co.jp Website: www.mipoxindia.com

CATHODIC ELECTROCOATING

athodic electro deposited coating is used extensively in the automotive industry. In this process, the component after phosphate pre-treatment is dipped in the bath of ecoat chemicals and is given an electric charge. The coating gets deposited on the component. The component is removed from the bath, washed and then baked. Th is process requires the following auxiliary equipment: hot water generator, RO water system, DI water system, laboratory and effluent treatment plant.

Coatec India Mohali, Punjab Tel: 0172 - 5090231 Fax: 0172 - 50963469 Website: www.coatecindia.com

OILS AND LUBES

ROTARY VANE OIL LUBRICATED VACUUM PUMP

otary vane oil lubricated vacuum pump is a sliding vane type direct or belt driven vacuum pump mounted on common base frames. The pump is compact in size, vibration free and hence, can be mounted inside the machines. It can attain vacuum levels of up to 29” of Hg with capacities ranging from 50 Lpm to 2000 Lpm. Specially treated vanes give advantage of silent operation and reduces wear and tear on stator. The unique design of lubrication system positively feeds minimum required oil to all rotating and frictional parts. Th is is useful in many applications like capsule fi lling / capsule printing machines and other pharmaceutical machineries, packaging / labeling machines, screen printing / plate making, book binding / folding machines, vacuum chucking etc.

Shree Siddhi Vinayak Industries Thane, Mumbai Tel: 022-28457073 Fax: 022-28458372

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Email: response@minivacpumps.com Website: www.minivacpumps.com

SOLUBLE CUTTING OIL

he soluble cutting oil forms emulsion with water and contains rust inhibited to protect from corrosion, rusting and biocide to prevent bacterial and fungus growth in emulsion. Th is oil features excellent cooling and lubricating properties which give exceptional surface fi nish and minimise tool wear. The oil is recommended for a variety of cutting operations on ferrous and non ferrous metals. Soluble cutting oil meets BIS – 1115 – 1986 specifications.

Eastern Petroleum Private Limited Mumbai, Maharashtra Tel: 022 - 2529 9990 / 91 / 92 / 93 Fax: 022 – 2524 1895 Email: office@easternpetroleum.in Website: www.easternpetroleum.in

OILS AND LUBES

COOLANT PUMP

he coolant pump is available in various types for use in machine tools. Th is pump comes in 25, 40, 63 and 100 LPM capacity in 120, 170, 220 and 270 steam lengths respectively. Performance of the pumps is as per the IS:2161 specifications. Appropriate protection is provided to prevent coolant entry into the motor.

Mototechnika Wadhwan, Gujarat Tel: 02752-243351, 09825223593 Email: alto_ad1@sancharnet.in Website: www.altopumps.com

COOLANT SEPARATOR

he coolant separators is of high quality made by using the fi nest raw materials. The mechanism of the coolant separator is such that the coolant fluid along with the iron dust particles falls to the inlet of the separators from the

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OILS AND LUBES

precision machine tools like grinders, milling machines, automats, etc. Coolants having iron impurities come into contact with the magnetic drum and remove all iron particles. The magnetic drum is kept clean at all times by a scrapper blade along the circumference.

Champion Industries Surendranagar, Gujarat Tel: 02752-231741, 09898166908 Email: champion_ind@yahoo.com Website: www.championindustries.co.in

ELECTRICAL DISCHARGE MACHINING OIL

he Electrical Discharge Machining (EDM) oil is a highly refi ned mineral oil with low viscosity. It is colourless, odourless and free of unsaturated hydrocarbons, making it operator-friendly. The oil, which is neutral and pure, can substantially reduce the chances of damaging effects on the skin of the operators. The low viscosity of the fluid improves flushing and fast particle settling which contributes to faster machining rates and fi ne surface fi nishes. Also, the low aromatic content of the fluid eliminates smoking during machining and higher fl ash point ensures safety of the environment. It has exceptional long service life due to stability towards thermal oxidation. It is used as a dielectric fluid in fi nish-cut electrical discharge (spark erosion) machining operations and in the manufacturing of electronics, extrusions, air-craft components, hardware, tools, fasteners, silver-ware, cutlery, valves and regulators etc.

Eastern Petroleum Pvt Ltd Mumbai, Maharashtra Tel: 022-2529 9990, 09821531709 Email: office@easternpetroleum.in Website: www.easternpetroleum.in

CUTTING FLUID

he cutting fluid is suitable for use in the simplest to the most demanding of cutting operations of complex alloys. Surface blackening of white metals,

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OILS AND LUBES

especially aluminium during metal working process may occur because of the metal working fluid used. The metal components of certain alloys of aluminium that contain zinc, copper and magnesium in varying percentages tend to react with ingredients of the metal working fluid like amino complexes but also other additives that are usually present. The cutting fluid minimises this issue.

Carl Bechem Lubricants (India) Pvt Ltd Bengaluru, Karnataka Tel: +91-080-22010800,+91-080-22010802 Mob: 09379917484 Email: info@bechemindia.com Website: www.carlbechem.com

FURNACE OIL FLOW HEATER

urnace oil has viscosity of 1500 sec redwood no.1 at 1000 F. With a fall in temperature, this viscosity goes further

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OILS AND LUBES

up making oil flow extremely difficult. To meet this demand, oil flow heaters have been designed. Th e heater is installed a little above the tank bottom. The heater does not heat the entire tank fi lled with oil. It only heats the oil that flows through the heater, thus cutting down the kilowatt rating. Installation is easy and safe. Its capacity ranges from 1 KW to 200 KW and oil flow is from 10 to 3000 LPH.

Email: marketing@fuchsindia.com Website: www.fuchsindia.com

FLUID PROCESSOR

he microfluidiser high shear fluid processor is available in low-volume benchtop version. Operating with the same fi xed-geometry interaction chamber technology of larger volume machines, this high shear fluid processor brings superior capabilities for uniform particle size reduction and cell disruption to samples as small as 1 ml.

Fuchs Lubricants (India) Pvt Ltd Mumbai, Maharashtra Tel: 022-66255900

Microfluidics Massachusetts, USA Tel: +1-617-9695452 Email: mixinginfo@mfics.com Website: www.microfluidicscorp.com

Vacunair Engineering Pvt Ltd Ahmedabad, Gujarat Tel: 079 - 22910771, 772, 773 Fax: 079 - 22910770 Email: info@vacunair.com Web: www.vacunair.com

METAL-FORMING LUBRICANT

he metal-forming lubricant is recommended for use in all medium-difficulty stamping, drawing and embossing operations on all grades of steel. Furthermore, this lubricant is also suitable for operations on non-ferrous metals, aluminium and galvanised steels. These products can be used on material thicknesses of up to 6 mm.

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MOTORISED VIBRATING SCREEN

otorised vibrating screen has applications in various industries such as chemicals, food, ceramics, sand and allied coarse, medium–fi ne applications. The vibrating deck is powered by a vibratory motor. The machine is available in different sizes. The amplitude and angle of throw can be changed to serve various applications. Wire mesh tightening feature is provided within the machine.

Premium Vijimech Pvt Ltd Ahmedabad, Gujarat Tel: 09712987467 Email: sales@vijimech.com Website: www.vijimech.com

POLYPROPYLENE PICKLING TANK

olypropylene pickling tank is made out of polypropylene thermoplastic. The tank is custom designed according to size and weight of load such as pipes, tubes, wire coils, bars, rods and structural steel. It is popularly used for pickling, degreasing, electroplating, rinsing, fluxing, anodizing, passivation, pre & post treatment and metal surface treatment. The tank is designed on German Software ‘RITA3.0’ and welded with modern reliable welding technology (Butt Fusion and Hot Gas Extrusion Process) which assures superior welding integrity.

Arvind Anticor Ltd Ahmedabad, Gujarat Tel: 079-32918016, 07878883400 Fax: 079-25894692 Email: info@picklingplant.com Website: www.picklingplant.com

ROLL FORMING MACHINE

old roll forming machine is built from prime material. The body and structure is stress relieved. It has a robust design and a heavy duty steel plate body. The alloy rolls are heat treated. Some of the features are easy replacement of parts, easy to

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operate, highly adaptable, economical, greater efficiency and longer life. It can be widely used in electronics and electric, fabrication and construction, steel furniture, automobile industries etc.

Godson Bending Systems Pvt Ltd Rajkot, Gujarat Tel: 0281-2361467, 2361449 Fax: 281-2361873 Email: godsonindia@hotmail.com

ROTARY AIR LOCK VALVE

otary air lock valve is available in various types like drop through, blow through, side entry type, sanitary type, double barrel type, vertical type, scraper type etc. Th is valve is manufactured in different constructions like C.I, C.S, SS 304, SS 316 etc. Rotary air lock feeder for materials ranges from granules to super fi ne powders. Its features include heavy duty outboard bearing, cast body for rigidity, airlock sealing, air purging for shaft sealing (optional) and direct drive or chain drive. Its size varies from 4” to 30” and can go higher. They are useful in material handling system, pneumatic conveying system, bag fi lter, cyclone separator and high temperature applications.

Ricon Engineers Ahmedabad, Gujarat Tel: 079-22744796, 65137270 Fax: 079-22761615 Email: info@ricongroup.com, riconengs@hotmail.com Website: www.ricongroup.com

ROTARY SCREW COMPRESSOR

he oil-free rotary screw compressor features precision machined rotors and gearing, advanced ultracoat rotor protection, anti-friction bearings, stainless steel air seals and a unique labyrinth oil seal design – all ensuring years of reliability and trouble free operation. Use of hydraulic valve instead of pneumatic valve, stainless steel rings along with labyrinth oil seals, stainless steel and aluminum piping ensures 100% oil free air all the time. The layout of the internal cooling components of the package is designed to ensure that the cooling of the package is optimized by keeping the compressor intake temperature low and allow the heat exchangers

GENERAL PRODUCTS

to keep their CTDs extremely low, thereby saving energy and money every day. Besides, Intellisys (a controller with fi nger touch control) provides fast diagnosis of system demand and displays a warning and/or stops the compressor if it exceeds operating parameters to keep troubleshooting expenses and downtime to a minimum.

Ingersoll Rand Industrial Technologies Ahmedabad, Gujarat Tel: 079 - 22820323, 22820123 Email: airsolutionsindia@irco.com Website: www.ingersollrandproducts.com

STEAM BOILER

team boiler has performance capacity 100 kg/hr to 2000 kg/ hr with operating pressure of 10 kg/cm2g. Smoke tube and water tube versions are available. MS seamless tube of asthma 106 GR-B is used. The unit will be equipped with high efficiency oil/gas burner. Air pre-heater

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arrangement gives high thermal efficiency 86+/-2% on NCV.

Aerotherm Systems Pvt Ltd Ahmedabad, Gujarat Tel: 079-25890158, 25834987 Fax: 079-25834987 Email: contact@aerothermsystems.com Web: www.aerothermsystems.com

STEPPING MOTOR DRIVE

tepping motor drive is available in both AC and DC input versions. It works on currents up to 4.4A and DC input voltage of up to 45V for low and medium speed applications. Some series of motors can work on currents up to 6A and 75 VDC operation. AC input drives are available operating from 55V AC to 230V AC. The drives are suited for high speed applications and are available with networking capabilities to operate with motors fitted with encoders. Special drives have been designed to operate with NEMA43 size motors and for motors designed to operate at high voltages. All the drives carry protection against shorting of the motor output terminals, under voltage and over voltage protection.

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They are all CE certified. They have specific digital inputs to turn current off which helps prevent overheating of the motors. All drives have micro stepping of up to 3200 steps/rev. Some drives can also be set to 4000 steps/rev. Some models carry an internal oscillator which makes running the motor at a predefi ned speed with a start stop signal without a pulse and direction signal. The drives are equipped with an electronic resonance damping circuit to reduce noise and mechanical vibrations at low and medium speed operation. Applications abound in labelling , packaging, ceramic tile printing, X-Y tables etc.

Strategi Automation Bengaluru, Karnataka Tel: 080-32329798, 32467879 Fax: 080-41163047 Email: sales@strategiautomation.com Website: www.strategiautomation.com

SUPER RIGID PRESS

uper rigid series power presses in the capacity rating of 10 / 16 / 25 / 40 / 63 / 80 /100 / 125 / 200 and 250 tonnes conform to the press standard both in terms of dimensions and geometrical accuracies. The machine incorporates modern design features and latest manufacturing practices. The press provides various features such as variable speed drive, manual or

motorised slide adjustment, pneumatic clutch, pneumatic counter balance, slide tool die holder, stroke counter, electro pneumatic safety control, manual or automatic centralised lubrication systems, hydraulics overload safety device, pneumatic die cushion die lifters, hydraulic die clamping etc. Application areas include sheet metal components for automotive / furniture / electronic and wide range of consumer goods industries.

Kawa Press Systems Pvt Ltd Rajkot, Gujarat Tel: 0281-2461102, 2461162 Fax: 0281-2461665 Email: info@shaileshmachines.com Website: www.shaileshmachines.com

SWING CHECK VALVE

FA lined swing check valve is ideal for use in highly corrosive and arduous conditions. It can replace swing check valves made from exotic alloys due to universal chemical resistance of the fluoropolymers lining. Th is valve can be used in horizontal as well as vertical installation because of the special design of the hinge pin, which enables the disc to achieve a seal without support of any system pressure. The 2 piece design

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GENERAL PRODUCTS

eliminates a potential leak path of conventional 3 Piece design with a seat face integrated in the body liner to seal against the disc in the closed position. The disc can swing freely within a piping system without interfering with the diameter of connecting pipe. The valve has fully PFA encapsulated one piece disc and hinge and PFA lined body. Range/Size: DN 40 (1.5”) – DN 400 (16”)

Dip-Flon Engineering & Co Ahmedabad, Gujarat Tel: 079-25624169, 25624003, 09227684378, 09898794440 Email: dipflon@sify.com

SOLID CARBIDE END MILL

olid carbide end mill offers smooth surface fi nish with its 6 effective teeth in fi nishing performance. The combination of heavy core diameter and unique flute constructions enables high rigidity, easy chip evacuation and vertical shear action. It is precisely grounded with eccentric form relief producing superior cutting edge for more strength and durability. 50° high helix geometry gives high cutting resistance along with high bending resistance for machining hard alloy steels, stainless steels, inconel etc.

Robin Precision Products Pvt Ltd Rajkot, Gujarat Tel: 02827-287634 Fax: 02827-287631 Email: info@bloodtools.com, sales@bloodtools.com Website: www.bloodtools.com

SURFACE GRINDING MACHINE

urface grinding machine comes with a design that makes easy movement of reciprocation table, provided with V and fl at (guide) ways lined with Turcite-B. It is hand scraped to achieve fi ne tolerances. The manual surface grinding machine has working surface with manual oil dip of 225 x 450 mm/300 x 600 mm. The wheel head spindle, hardened and ground, runs on precision angular contact

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GENERAL PRODUCTS

bearings with imported grease and driven by fl ange mounted motor through flexible couplings. The wheel head micro feed is 0.002 mm.

Atul Machine Tools Rajkot, Gujarat Tel: 0281-2360227, 09227602034 Email: info@atulmachine.com Website: www.atulmachine.com

WIRELESS DATALOGGER SYSTEM

he wireless data logger system measures temperature, humidity and saves the recorded measurement data sent to the central base at regular intervals. If a limit value is exceeded, a radio link is established immediately. In the free field, the transmission path is approximately 100 m at a frequency of 2.4 GHz.

Testo India Pvt Ltd Pune , Maharashtra Tel: +91-020-65600203, 09375346186 Email: apatankar@testoindia.com Website: www.testo-india.com

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CHEMICAL RESISTANT DIAPHRAGM VACUUM PUMP

hemical resistant diaphragm pump is the best suited oil free vacuum option for laboratory and pilot scaled application. Typical applications for chemical resistant diaphragm pump includes evacuating chemically aggressive gases and vapors from such equipment as rotary evaporators, vacuum drying cabinets and centrifugal concentrators. Most importantly, diaphragm pumps is oil-free for vastly reduced service demands compared with oil-sealed pumps. It eliminates the water waste of water-jet aspirators and the contaminated waste-oil disposal of rotary vane pumps.

Sri Vishnu Pumps Mfg. Co. Thane, Maharashtra. Tel: 022-28458372, 28457073 Email: vishnupump@rediffmail.com Web: www.minivacpumps.com

V-BELTS

-belts are available in a range of cogged belts, banded V-belts, variable speed belts, etc. All SWR Europe V-belts are electrically conductive (anti-static) to DIN ISO 1813. These are suitable without restriction for use in tropical regions and are oil and heat-resistant up to 120째C.

Belcon Engineers Pvt Ltd Mumbai, Maharashtra Tel: 022-28575318, 28575320 Email: sales@belcon.co.in Website: www.belconengineers.com

2500 AMP ACB PANEL

he ACB panel is used to make energy distribution safer, minimise maintenance cost and reduce installation time.

Deep Automation Faridabad, Haryana Tel: 0129-4056729, 09873671946 Email: automation_deep@yahoo.com Web: www.deepautomation.in

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GENERAL PRODUCTS

TRI-LOBE ROTARY BLOWERS

he tri-lobe blower is suitable for use in air/gas applications. It is ruggedly built and can work under tough conditions, high transmission loads and higher operating speeds with capacities up to 65,000 m 3/ hr and pressure up to 1.1 kg/cm 2 in single stage and up to 2.2 kg/cm 2 in multi stages. The computer generated new millennium series rotor lobe profi le optimises high volumetric efficiency, minimises slip losses, lowers power consumption and thus are energy efficient.

Swam Pneumatics Pvt. Ltd. Noida, Uttar Pradesh Tel: 0-120-4696222,2527610 Email: sales@swamatics.com Wesite: www.swamatics.com

FIRE ROLLING SHUTTERS/ FIRE DOORS

ire rolling shutters/fi re doors are constructed of galvanised or stainless steel in a variety of gauges, slat designs and fi nishes for unsurpassed strength, durability and style. Wide ranges of styles meet or exceed industry fi re safety testing standards including UL, FM and ULC. The doors are also compliant with all

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NFPA-80 Standards. The door closes automatically under governor control after separation of fuse link. UL-listed brush-type smoke gaskets meet the smoke retardation requirements. Additional safety options include the fi re SentinelTM time-delay release device photoelectric or ionisation-type smoke detectors, with or without heat detector. Additionally available uninterruptible power supply for use with motor-operated doors allows door closure by central alarm or smoke detector under motor power. 2â&#x20AC;&#x201C;4 hours fi re-rated resistance.

Gandhi Automations Pvt Ltd Mumbai, Maharashtra Tel: 022-66720200/66720300 Fax: 022-66720201 Email: sales@geapl.co.in Website: www.geapl.co.in

CYLINDRICAL PHOTOELECTRIC SENSOR

he CY series cylindrical photoelectric sensor has a M18 thread size for convenient mounting in industries. It has a long sensing range up to 12 metre throughbeam type, 3 metre through retro-reflective type and 120 mm through diff use-reflective type. Th is sensor has a wide product range with DC supply type 10 to 30 V DC and AC supply type 24 to 240 V AC. It is used in industries such as ceramic, packaging, pharmaceuticals, food processing, automobiles, textile and plastics among others.

Lubi Electronics Ahmedabad, Gujarat Tel: 079-22205471, 09825569559, 09327497006 Email: info@lubielectronics.com Website: www.lubielectronics.com

COPPER ENAMELLED WIRE

he wire is manufactured using EC grade copper rods that are extruded or drawn by dies of special size and are further repeatedly coated with enamel. Various varieties of enamelled copper wire comprise polyester, polyesterimide and selfsolderable wires. For example, polyesterimide overcoated with polyamide-imide enamelled round copper wire, class 200; modified

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GENERAL PRODUCTS

polyester enamelled round copper wire, class 155; polyester enamelled round copper wire, class 130; all in the range of 4.06-0.091 mm (8-43 swg). Polyestermide enamelled round copper wire, class 180, in the range of 4.060.091 mm (8-43 swg). Self solderable polyurethane enamelled round copper wire, class 155 & 180, both in the range of 0.813 mm to 0.091 mm (21 swg to 43 swg).

Jalan Wires Pvt Ltd Mumbai, Maharashtra Tel: 022-61451600 Email: sales@jalanwires.com Website: www.jalanwires.com

MOTOR PROTECTION RELAY

otor protection relay displays various parameters, trip count and trip data on 8-digit alphanumeric display and has separate LEDs for individual fault indication. Th is is a four user programmable output relay, its built-in self-supervision and selftesting feature helps maintenance. Th is provides easy operation by 5 push buttons. It has RS485 Port for serial communication with ‘MSCOM’ user-friendly software.

Larsen & Toubro Ltd Mumbai, Maharashtra Tel: +91-022-67054902 Email: karthikm@lntebg.com Website: www.lntebg.com

ELECTRIC WIRE ROPE HOIST

he electric wire rope hoist is available from 0.5–50 tonne capacity range with a maximum height of lift of 200 mtr in accordance with Class I, II, III & IV heavy-duty specification as per IS:3938-1983. Th is wire rope hoist is manufactured offering foolproof electro-mechanical brakes operating on conical rotor motor principles. The brakes are far superior to electro-hydraulic thrustor brakes offered by most other manufacturers. All hoists have high torque, crane duty, 40%

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GENERAL PRODUCTS

CDF, Class-F insulated conical motors suitable for 150 starts/hour. Brakes are provided in hoisting as well as cross traversing motion.

Eddycranes Engineers Pvt Ltd Mumbai, Maharashtra Tel: +91-022-23522710 Email: eddycranes@vsnl.com Website: www.eddycranes.com

SPINDLE MOTOR

he Fanuc spindle motor Beta-iI series is a high performance motor suited to spindle axis of machine tools. High efficiency and low heat generation is achieved by spindle HRV control. Optimised winding design & effective cooling structure enables high power and high torque. Th e compact size of the motor is an added advantage.

ELECTRONIC SAFETY SENSORS

he RSS-36 electronic safety sensors are equipped with RFID technology, with different variants, each with different coding possibilities. These sensors also feature all the well-known advantages of the CSS technology. The second version only accepts the target, which was taught during the fi rst startup. In the third version, the teach-in process can be repeated any number of times.

Schmersal India Pvt Ltd Pune, Maharashtra Tel: 020-26741000 Fax: 0-1244342333 Email: info-in@ schmersal.com Website: www.schmersal.in

GE Fanuc Automation Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com Website:www.fanucfa.com

STEEL BARS

teel bars are processed with center-less grinding and hard chrome plating after cold drawn. The bar is abrasion-proof & corrosion-proof. These are hard chrome coated where thickness is minimum 20 microns. Standard length of mass product is 3000 mm -6000 mm.

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Fu-Long Metal Industrial Co Ltd Taoyuan Hsien-Taiwan Tel: 886-3-4852858 Fax: 886-3-4787597 Website: www.flweb.com.tw

MAGNALED SPHERE

agnaled sphere is the latest breed of top quality and high class LED OT light. It has a touch screen control and lux, kelvin and CRI adjustments which will give natural colour rendering even after years of light use. It has a penetration depth of 1500mm, giving excellent visibility of deep cavities & tissues as compared to all other lights which normally have only 800 â&#x20AC;&#x201C; 1000 mm. It provides multiple options of single dome/double dome /ceiling mounted/ mobile with battery backup/mobile spot light and 360 degrees maneuverability with touch of a fi nger.

Magnatek Enterprises Hyderabad, Andhra Pradesh Tel: 040-66668036/ 6550 1094, 09348028160 Email: sales@magnatekenterprises.com Website: www.magnatekenterprises.com

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HEATER POWER CONTROLLER

ompact 3 phase SCR power controller for electrical heating loads ranging from 1.5 KW to 12 KW/3-phase. Heavy duty Terminal connectors are provided for AC 3 phase supply, control signal and heater wires. The entire assembly is mounted on MS powder coated plate/ enclosure, which in turn can be easily fi xed inside the closed control panel as desired. Potentiometric settings are accessible to the user for on-site calibrations, max/min voltage output and ramp up / ramp down time adjustments. Th is model accepts the control signal from external DDC, PID or PLC controller in the form of 0-5 V, 0-10 V mA user selectable control signals.

Libratherm Instruments Pvt Ltd Mumbai, Maharashtra Tel: 022-28963823, 09821136685 Email: libratherm@libratherm.com Website: www.libratherm.com

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MULTI-FLUTE THREAD MILLS

he expanded range of TMSD multi-flute, single point thread mills are supplied with cutting diameters from 13mm and up to 36.5mm and in pitches from 0.5mm up to 8mm (48 to 3 TPI),adjustable overhang (up to 144mm) for optimal stability.

Vargus Ltd Nahariya, Israel Tel: +972-4-9855111 Email: mrktg@vargus.com Website: www.vargus.com

CUTTING VALVES

he cutting valves enable longer production runs resulting in increased production of parts. These are very compact, lightweight design allows the valves to be placed closer together for greater versatility. The new stems

GENERAL PRODUCTS

deliver greater performance for longer production runs with many on-off cycles. Six stainless steel springs increase reliability and production and the compact design enables close stacking of the cutting head.

Karolin Machine Tool (KMT) Pvt Ltd Mumbai, Maharashtra Tel: 022-28572494 Email: bhavin.mavani@kmt-waterjet.com Website: www.kmt-waterjet.com

HYDRAULIC SHEARING MACHINE

he hydraulic shearing machine steel plate is rigid in order to provide accurate bending. Th ree speed operations reduce ideal travel time which improves productivity. Piece guide slide is lubricated by central hand pump. It has moveable console with emergency stop and tonnage indicating adjustment device. Bending force is easily adjustable from front for tool of bending material.

Jekson Machinery Pvt Ltd Ahmedabad, Gujarat Tel: 079-65259895, 9426510343 Email: info@jeksonmachinery.com Website: www.jeksonmachinery.com

PUMPS

-Series Air-Operated DoubleDiaphragm (AODD) pumps are self-priming and provide gentle displacement of fluids. They are equipped with the patented PERSWING P速 air control system, which ensures accurate reversal of the main piston and is characterized by low noise levels. They are created from a solid plastic block, offering advantages like increased pump security due to an innovative ring-tightening structure, increased capacity, decreased air consumption, reduced noise level, optimized flow pattern and a pulsation damper suitable for fl ange connection.

Dover India Pvt Ltd Chennai, Tamil Nadu Tel: 044-26271020 Email: akmurthy@destaco.com Website: www.doversolutions.co.in

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GENERAL PRODUCTS

UPS SYSTEMS

rykard E-Green UPS systems are available in 3, 5, 6, 7.5 and 10 kVA ratings for aingle-phase I/O models. External batteries supplied along with the UPS systems support loads for backup times ranging from 15 min to 4 hrs depending on the confi guration of batteries. Salient features include: efficient and pay for itself, no electrical pollution, total protection and reliability, online diagnostics, contemporary design, etc.

Alacrity Electronics Ltd Chennai, Tamil Nadu Tel: 044-39122146, 09380113296 Email: ael@alacritymail.com Website: htwww.alacrityelectronics.co.in

FUEL PUMP

uel pumps has 600 models of fuel units to choose from, the right model for ones application. Small capacity burner are from 10 to 1000 kw for light oil, kerosene applications, pumps with or without solenoid valve. For single step or two step operation, models available are AN, AL, AS, AT, A2L. Medium capacity burner

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are from 400 to 3000 kw for light oil or heavy oil applications, pumps with or without hydraulic cut-off model D,AJ,E,J. High capacity burner are from 3000 to 30 000 kw. Pumps with electric preheater facility for heavy oil applications models T,TA etc.

Classic Enterprises Mumbai, Maharashtra Tel: 022-2203 4496 Email: classic@bom3.vsnl.net.in Website: www.classic-combustion.com

GOLIATH CRANES

he single girder and double girder goliath cranes conform to IS:807-1976, IS:31771977, IS:3938-1983 and IS:4137-1963 wherever applicable. These cranes are manufactured up to 50 ton capacity and for 40 m span. Grabbing cranes are designed to suit indoor or outdoor location and can also be supplied with grab buckets, electromagnets. Goliath cranes are designed to run on forged steel wheels running on L-type housing on anti-friction roller bearings. These cranes are suitable for control from floor, by means of pendant controller or from the driverâ&#x20AC;&#x2122;s cabin by means of master controller or through radio remote control.

Elmech Engineers Mumbai, Maharashtra Tel: 022-2352 1798/2710 Email: eddycranes@vsnl.com Website: www.elmechengineers.com

DONOR CHAIR

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he 4R4213 is a fully upholstered donor chair, designed to provide a comfortable position for the donor, and features variable positioning for either arm, as well as reclining and upright body positions. Power slide control provides smooth shifting from head-low, feet-high position to any intermediate position. Adjustable arm rests swing out for easy seating, as well as moving up and down.

GENERAL PRODUCTS

The armbar assembly is available for operatorâ&#x20AC;&#x2122;s ease and solid arm support.

Remi Elektrotechnik Ltd Mumbai, Maharashtra Tel: 022-40589888, 09820627422 Email: sales@remilabworld.com Website: www.remilabworld.com

ROBOTIC MACHINES

he robotic machines are accurate, minimize problems when parts are placed in machines incorrectly and decreases the labour cost to great extent. These robotic machines are made using best available modern techniques by the skilled and expert professionals.

Welding Technologies India Pune, Maharashtra Tel: 020-65101340 Email: wti@weldingtechindia.com Website: www.weldingtechindia.com

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BOP DRILLS

device so that when correctly installed and maintained, no steam regardless of its pressure can enter the mixing chamber until the water flows to raise the steam valve of its seat.

ield coil and armature are fully shielded by the motor housing. The resultant distortion rigidity allows for reliable, quiet and vibration free work â&#x20AC;&#x201C; even when used in permanently tough conditions or with extreme shock and load impacts. The barrel design also offers an impressively long drill service life and makes for easy maintenance.

Fein Power Tools India Pvt Ltd Chennai, Tamil Nadu Tel: 044-43578680, 09825063597 Email: info@fein.in Website: www.fein.in

WASHDOWN STATION

he washdown station (mixing battery) is designed to provide instantaneous hot water economically by mixing steam and potable water to the required temperature. Mixing battery provides food, beverage, and pharma and cosmetics industry with economical hot water for cleaning applications wherever steam is available. It incorporates hydraulic fail safe

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Feliz Biotech Industries Mumbai, Maharashtra Tel: 022-2685 9440, 9892273314 Email: roque_ferns@rediffmail. com Website: www.felizbiotech.com

DRILLING UNITS

BM 80 U and KBM 80 auto offers mechanical three-speed gearbox with continuously variable electronic speed reduction means optimum cutting speed for core drilling, drilling, thread cutting, countersinking and reaming. It provides flexible tool use and high concentricity due to a combination of QuickIN and MT 3 holders. High

GENERAL PRODUCTS

torque, high power motor for efficient core drilling up to 80 mm and thread cuts up to M 27. High levels of work safety due to extensive safety package including torque slipping clutch, visual magnetic holding force display and viseo touch pad controls.

Fein Power Tools India Pvt Ltd Chennai, Tamil Nadu Tel: 044-43578680, 09825063597 Email: info@fein.in Website: www.fein.in

ELECTRIC BELT HOIST

he XB electric belt hoist is designed for a sterile environment, where contamination is a risk. It can lift from 500 kg to 2,000 kg. The long-life belt can withstand immersion in boiling water, is acid-resistant, and unaffected by solvents. A lifting height of up to 9 meters and a 2-speed motor ensure easier handling of the load.

Konecranes India Pvt Ltd Pune, Maharashtra Tel: 020-40047470, 09892273314 Email: india.sales@konecranes.com Website: www.konecranes.com

BOTTLE FILLING MACHINE

he compact automatic volumetric high-speed bottle liquid fi lling machine consists of turntable, SS slat conveyor belt, fi lling and post gassing SS-316 nozzles, precision built SS-316 syringes, non-toxic synthetic rubber tubing, easy-to-reach compact panel and no container no fi lling system, etc. Th is compact, matt fi nished unit is totally enclosed in stainless steel. Th e un-scrambler is designed in the machine to eliminate dead ends and difficult to clean spot. All exposed parts are made of SS-304, matt fi nish to avoid any reflection.

Laxmi Pharma Equipment Ahmedabad, Gujarat Tel: 079-2583 1600 Email: laxmipharma1@dataone.in Website: www.arhan.co.in

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GENERAL PRODUCTS

DATA ACQUISITION SYSTEMS

he Absorptometer E determines oil absorption number. Th is instrument and burette does not stop automatically, enabling evaluation acc B and C of ASTM 2414. The principle consists in measuring resistance which carbon black puts up against the rotating blades during oil addition. It also determines the carbon black oil absorption.

Brabender GmbH & Co KG Duisburg, Germany Tel: +49-203-77880 Email: plastics-sales@brabender.com Website: www.brabender.com

PLATE BENDING MACHINE

ydraulic / mechanical 4 rolls / 3 rolls standard prepinch type and pyramid type plate bending machines are available in wide range from 1,000 mm to 6,000 mm length and 1 mm to 100 mm thickness. The machine features movable control panel, gear box / hydraulic motor, MS plates,

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fabricated main frame, housing with forged steel rolls and hydraulic and electrical balancing system. Moreover, it has the advantage of easy maintenance, simple mechanism enable, suitable for medium and heavy plates and pipes in full circle or various radius can be done easily. The machine also comes with the accessories like conical bending, section bending and plate feeding table etc.

Weldor Engineering Pvt Ltd Rajkot, Gujarat Tel: 0281 - 2360242, 2360243, 44 Fax: 0281 - 2360466 Email: weldor@weldor.com Website: www.weldor.com

FLANGES

langes come in ranges of 15 Nb up to 600 nb in 150 lbs , 300 lbs, 400 lbs , 600 lbs , 900 lbs , 1500 lbs , 2500 lbs / table 2.5 , Table 6 , table 10, table 16,table 25 , table 40, table 64, table 160, table 320, table 400

Gopal Forge Industries Mumbai , Maharashtra Tel: 022-67496240 Email: gopalforge@yahoo.com Website: www.gopalforge.com

METALLIC CONVEYOR BELT

he metallic conveyor belt achieves high standards of engineering and construction. One can choose from different types of standards. Belt weaves are often used for diverse belt applications across the entire span of industry. They are useful when additional strength is required and belttracking needs to be controlled. Flat wire belt is the economical strongman of conveyor belt family. It is available in different belt specifications, the metallic conveyor belt is manufactured with various types of belt edges.

T N F Engineering Navi Mumbai , Maharashtra Tel: 022-2761 9185 Email: tnf@vsnl.com Website: www.tnfengg.com

FOOD-GRADE LUBRICANTS

complete range of food-grade lubricants those conforming to NSF H-1 regulations and 21 CFR 178.3570 are available. These are odourless, colourless and tasteless. The lubricants have the ability to function in very high/low temperatures, water resistance, neutral behavior towards synthetic components, resistance to chemicals, steam, vapour & foodstuff.

Integrated Technology Navi Mumbai, Maharashtra Tel: 022-3298682, 09323806743 Email: contact@integ-tech.net Website: www.integ-tech.net

TORQUE MEASURING FLANGES

s a system, the KiTorq with fully digital transmission offers an accuracy of 0.05 per cent and a signal bandwidth of up to 10 kHz with maximum dynamic response and precision. A speed sensor with 60 pulses per revolution is already

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GENERAL PRODUCTS

incorporated in the standard model.

Kistler Instruments India Pvt Ltd Faridabad , Haryana Tel: 0129-4113555 Email: sales.in@kistler.com Website: www.kistler.com

NETWORK SENSOR

his is a rugged, self-contained point-to-point wireless network that provides reliable confi gured I/O for remote sensing and actuation. It is designed for process and assembly/manufacturing automation, agriculture monitoring, remote tank level management and wastewater treatment installations. Applications also include robotics, crosswalk signal actuation, machinery monitoring, rotating machinery and many others. It delivers two-way RX/TX communication with full acknowledgement at range up to 4.8 km (3 miles) in line-of-sight. It uses the frequency hopping spread

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GENERAL PRODUCTS

spectrum protocol for data communication in an industrial environment.

connected gear type pump. The capacity of trucks is 1,000 kg, maximum lift height is 3,000 mm, service weight is 2,000 kg and battery is 24 V.

Banner Engineering India Pvt Ltd Pune, Maharashtra Tel: 020-6640 5624, 09322339208 Email: salesindia@bannerengineering.com Website: www.bannerengineering.com

TIMING BELTS AND PULLEYS

iming belts and pulleys come with unique features. Positive grip of the belts with pulley grooves eliminates slippage and speed variation. There is no variation and no elongation because of cable tension member. Its features include positive slip-proof engagement, wide range of load and speed capacities, freedom from high tension, compact design, constant angular velocity, minimum backlash, high mechanical efficiency, lightweight and quiet operation, economical, etc. The timing belts and pulleys conform to ISO:5294 quality standards.

Kwedos Belt Drives Pvt Ltd Ahmedabad, Gujarat Tel: 91-079-25507367,09925111749 09925111749 Wesite: www.kwedospulleys.com

HYDRAULIC HANDLIFT PALLET TRUCK

he hydraulic handlift pallet truck is offered in standard capacities of 1.1, 2, 2.5 and 3.2 tonne and has a standard fork length of 900 mm, 1,050 mm and 1,220 mm respectively. Minimum pallet gap varies from 65 to 100 mm. For special applications, pallet truck is tailor-made to suit customerâ&#x20AC;&#x2122;s requirements of capacities up to 10 tonne, fork lengths up to 1,650 mm, and pallet gap up to 250 mm and even more. Ram and plunger used in the hydraulic units are hard chrome plated and mirror fi nished.

Agromec Meerut, Uttar Pradesh Tel: 0121-2440660, 3098766, 09313159058 Email: agromec@vsnl.com Website: www.agromecindia.net

CTR Manufacturing India Ltd Pune, Maharashtra Tel: 020-26633402 Email: handlingequipments@ctr.in Website: www.ctr.in

REACH LIFT TRUCK

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each lift truck CLR1 has an electromagnetic brake mechanism mounted directly to the top of the drive motor. It has transistor-controlled pump motor driving direct

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HEAVY DUTY LATHE MACHINE

eared head extra heavy duty lathe machine is available in different heights of centre up to 1066 mm, length of bed ranging up to 12,000 mm and admit between centres up to 11,000 mm. Main spindle hollow ranges 150 mm. Dynamically balanced spindle enables the spindle to run with vibration free motion at 200 rpm. Spindle carries the 10 T job weight. All gears are made of 20MnCr5 material and are fully induction hardened. The Norton gear box is able to cut any of the metric, modules and pitch (D.P). Bed is made from graded cast iron and fl ame hardened up to 400 BHN diametral. Face plate, carrier plate, steady rest, follow rest, motorised coolant pump with tank and fittings, rear tool post, quick change tool post are offered.

Vinit Engimech Pvt Ltd Rajkot, Gujarat Tel: 0281- 2312091, 2311734 Fax: 0281- 2311935 Email: vinit@balajilathe.com Website: www.balajilathe.com

VALVE STEM PACKING

he valve stem packing is made from 100 per cent virgin PTFE. Its unique fibril, structure and highly pliable material conform to worn stems and packing boxes, thus eliminating the needs for costly downtime and repair. The construction enables products to get squeezed in all directions and fi ll in the voids. It is used in a number of industries such as chemical manufacturing, pharmaceutical plants, petrochemical production, steel manufacturing, paper and pulp processing, power generation, marine, distilling, food equipment manufacturing, food and beverages processing, etc.

MAS Sealing Systems (P) Ltd Mumbai , Maharashtra

GENERAL PRODUCTS

Tel: 022-2850 1805/8251 Fax: 0281- 2461665 Email: masseal@vsnl.com, info@Shaileshmachines.com Website: www.masseal.com

KNIFE GATE VALVES

nife gate valves are available in various ranges. The rising gate clean sundries on the seal surface automatically. Stainless steel prevents leaking, which is caused by corrosion. Short face-to-face saves raw materials and installation room and support intensity of the pipe effectively. Triangular yoke saves raw materials and ensures mechanical performance.

Zhejiang Gaochuang Pump Valve Co Ltd Tel: +86-577-6798 8958 Email: trade@chinagaochuang.com

BUTTERFLY VALVES

utterfly valves range includes rubber lined, PTFE lined, metal sealing and high performance valves. They are suitable for water, oil, chemicals and treatment plants and operated by pneumatic actuator and electric actuator. The electric operated

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GENERAL PRODUCTS

valves are operated as on/off application with 230 V AC. The size ranges from 1” to 48”.

M Kumar Technocrates Ahmedabad , Gujarat Tel: 079-27540287, 09898114242 Email: info@amtechvalves.net Website: www.amtechvalves.net

HANDHELD THERMAL IMAGING CAMERA

onocular is a handheld thermal imaging camera that lets law enforcement officers to watch clearly in total darkness providing an undeniable tactical advantage. It also includes features that enables watching suspects in total darkness, see through smoke, dust and light fog, see through camoufl age and foliage in any lighting conditions, see more and farther than other low-light night vision goggles and cameras. FLIR’s advanced imageprocessing algorithms produce crisp and clear thermal video, whether it is day and night or good and bad weather.

Flir Systems India Pvt Ltd New Delhi Tel: 011-45603555 Fax: 011-47212006 Email: flirindia@flir.com.hk

BOOSTER PUMPS

he machine is totally enclosed, fan cooled and has an AC induction motor for complete absence of suction trouble. It is suitable for long-hour duty. Motor stator, made of low-watt loss steel laminations is assembled under pressure and rigidly locked in the frame. The varnish impregnated windings offer excellent resistance power. All single-phase versions up to 1.0 HP are incorporated with thermal over-load protector. With flow rate up to 60 lpm, head up to 36 metres and suction lift from 6 metres, it comes with a bronze impeller with mechanical seal of carbon and ceramic and has the capacity to handle turbidity up to 50-ppm silica scale.

Oswal Pumps Ltd Karnal, Haryana Tel: 0184 6616600 Fax: 01748 257700 Email: munishrai@oswalpumps.com Website: www.oswalpumps.co.in

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INTELLIGENT POWER FACTOR CONTROLLER

he instrument can display six parameters for current, voltage, frequency, kVAR, power factor and temperature. Th is unit has a current and voltage multiplying factor set directly from the front panel and highâ&#x20AC;&#x201C;low alarm limit settings for all six parameters. Capacitor values can be set directly and separately in each stage. In the event of power failure, all the data stored in this instrument is preserved for at least two months.

Goliya Instruments Pvt Ltd Mumbai, Maharashtra Tel: 022-24149657, 24179467 Fax: 022-24130747 Email: goliya@mtnl.net.in Website: www.goliyainstruments.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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EVENT LIST

NATIONAL

14-16 December 2012 IPVS TRADE FAIR & CONFERENCE 2012 Focus: Industrial pumps, Valves & systems Where: Auto Cluster Exhibition and Convention Centre, Pune, Maharashtra Tel: 022 2410 2801/02 Fax: 022 24102805 E-mail: harikrishnan@orbitzexhibitions.com

ABROAD

11-14 December 2012

5-8 December 2012

AUTOMECHANIKA SHANGHAI Focus: Repair & Maintenance Equipment Where: Shanghai New International Expo Center, Pudong, Shanghai Tel: 86 21 6160 8555 Fax: 86 21 5876 9332 E-mail: info@china.messefrankfurt.com

MANUFACTURING INDONESIA SERIES 2012 Focus: Manufacturing machinery, equipment, materials & services and chemical processing Where: Jakarta International Expo, Jakarta, Indonesia Tel: 65 2333 6777 Fax: 65 6233 6768 E-mail: enquiry@iemallworld.com

NATIONAL

8-13 January 2013

4-6 January 2013

VIBRANT GUJARAT GLOBAL TRADE SHOW Focus: Manufacturing & technology Where: Helipad Ground, Gandhinagar, Gujarat Tel: 079 2325 6009, 2325 0492 / 93 Fax: 079 2325 0490 E-mail: indextb@indextb.com

ELASIA 2013 Focus: Electrical, Lightings & Power sector Where:BIEC, Bengaluru, Karnataka Tel: 080 43307474 Fax: 080 22352772 E-mail: info@triuneexhibitors.com

ABROAD

7-10 January 2013 ARABIA ESSEN WELDING & CUTTING Focus: Manufacturing Industry Where: Dubai World Trade Centre, Dubai, United Arab Emirates Telephone: 49 20172440 Fax: 49 2017244248

NATIONAL

14-18 February, 2013

15-17 February, 2013

VCCI EXPO Focus: Industrial and Allied products Where: Naulakhi Compound, Vadodara Tel: 0265 - 2642291, 2636262, 2636969 Fax: 0265 - 2638050 E-mail: info@vcciexpo.org

IETF MANUFACTURING Focus: Manufacturing Industry Where: Pragati Maidan, New Delhi Tel: 0124)-4014060 / 4014061 Fax: (91)-(124)-4014088

ABROAD

5-7 February, 2013 EXPO MANUFACTURA 2013 Focus: Manufacturing Productivity Where: Cintermex, Monterrey, N.L., 64010, Mexico Tel: 52 (81) 8369 6969 Fax: 52 (81) 8369 6911 E-mail: info@cintermex.com.mx

CUT HERE

Invites You To Indiaâ&#x20AC;&#x2122;s Largest

SME Gathering

200+ participants | 15,000+ business visitors expected | 8,000+ products on display Business transactions worth ` 48 crore expected | Spread over 4200 sq mtr Showcasing more than 30 diverse industry categories.

CHE NNA I

22 - 25 November 2012 Chennai Trade Centre 10 am - 7 pm

CUT HERE

Exhibitor Profile

EVENT LIST

ABROAD

6-7 March, 2013

19-21 March, 2013

19-22 March, 2013

DESIGN & MANUFACTURING SOUTH Focus: Technology Where: Orange County Convention Center, Orlando, US Tel: 310-445-4200 E-mail: info@cancom.com

ELECTRONICA & PRODUCTRONICA CHINA 2013 Focus: Materials processing, production related services Where: Shanghai New International Expo Centre Tel: +86-21-2020-5503 Fax: +86-21-2020-5688 E-mail: dong.yongfa@mmi-shanghai.com

AMPER 2013 Focus: Electronics, automation Where: Brno Exhibition Centre Tel: +420 221 992 144 Fax: +420 221 992 139 E-mail: kurdiovsky@terinvest.com

NATIONAL

ABROAD

17-18 April, 2013

17-20 April, 2013

8-10 April, 2013

FASTENER FAIR INDIA 2013 Focus: Plant & Machinery, Tools & Tooling Equipment Where: Bombay Exhibition Centre, Mumbai Tel: +91 (0) 124 452 4207 Fax: +91 (0) 124 452 4227 Email: fastenerfair.india@interads.in Website: http://www.fastenerfair.com

BLECH INDIA 2013 Focus: Sheet Metal Working Where: Bombay Exhibition Centre, Mumbai Tel: +91 124 452 4207 Fax: +91 124 452 4227 Email: blech.india@interads.in Website: http://www.blechindia.com

CHINA (SHANGHAI) INTERNATIONAL WIND ENERGY EXHIBITION AND CONFERENCE Focus: Wind energy Where: Shanghai New International Expo Centre (SNIEC), Shanghai, China Tel: +86-21-51978782 51978781 51978780 Fax: +86-21-51010898 Email: cwee@mpzhongmao-dr.com Web: www.cwee.com.cn

NATIONAL

6-8 May 2013 RENEWABLE ENERGY WORLD INDIA Focus: Renewable energy generation, T&D Where: Bombay Exhibition Centre, Goregaon, Mumbai Tel: +44 (0) 1992 656 621 (Int) +91 (0)124 452 4231 (Ind) Fax: +44 (0) 1992 656 700 E-mail: jyotsna@interadsexhibitions.com

ABROAD

14-16 May 2013

14-15 May 2013

DESIGN & MANUFACTURING CANADA 2013 Focus: Manufacturing equipment, components Where: Toronto Congress Centre, Toronto, Canada Tel: +1 (416) 245 5000 Fax: +1 (416) 245 4923 E-mail: mailbox@torontocongresscentre.com

SMARTENERGYMARKET SEM Focus: Intelligent grids, energy storage solutions Where: MunichExpo Veranstaltungs GmbH, München, Germany Tel: +49 (0)89/322991-16 Fax: +49 (0)89/322991-19 E-mail: tobias.ulmer@munichexpo.de

PUNE November 2-5, 2012 INDORE January 11-14, 2013

CHENNAI November 22-25, 2012

AURANGABAD February 1-4, 2013

LUDHIANA December 21-24, 2012

RUDRAPUR February 23-26, 2013

HYDERABAD May 31-June 3, 2013

Tel: 022-30034651 • E-mail: engexpo@network18publishing.com • Web: www.engg-expo.com

ENGINEERING EXPO AHMEDABAD 2012

AHMEDABAD October 5-8, 2012 Gujarat University Exhibition Hall

E The Chief Guest BB Swain (centre) inaugurating the Engineering Expo Ahmedabad 2012 in the presence of Sunil Shah (second from left) and Richard Moore (third from left)

pitomising ntrepreneurial xcellence

Gujarat, a manufacturing hub housing a large number of medium & small-scale units (SMEs), multinational companies, etc., has witnessed tremendous industrial growth in the last few years. The recently held Engineering Expo Ahmedabad 2012 succeeded in adding further impetus to this growth by offering the manufacturing fraternity, especially the SMEs in the segment, a perfect platform to boost business and proﬁts. Meeting the expectations of exhibitors and visitors alike, the Expo has reached yet another milestone and promised to deﬁne new horizons in its next edition. A report…

AVANI JAIN

ujarat, renowned for its vibrant and buoyant economy, has been at the forefront of industrial growth, thanks to the entrepreneurial culture of its people and strong infrastructure focus of its policy makers. In this backdrop, the 11th edition of Engineering Expo Ahmedabad, held from October 5-8, 2012, proved to be a catalyst in accelerating this growth further by bringing the industry veterans from the manufacturing sector, especially SMEs, together under one roof and offering ample business opportunities. Organised by Network 18 Publishing, the Expo has emerged as one of the major trade platforms for the industry.

GRAND OPENING The inauguration function was graced by the presence of Chief Guest B B Swain, Vice Chairman & Managing Director, Gujarat Industrial Development Corporation; Richard Moore, Group Manufacturing Manager, UK Carbon & Graphite Company; Sunil Shah, Chairman,

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Gujarat Innovation Society; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing; and Archana Tiwari-Nayudu, Executive Editor, SEARCH, Network 18 Publishing. Engineering Expo Ahmedabad was well-organised. It was not only appreciated by industry veterans from the country but professionals from abroad were also overwhelmed to see an event like this being organised on such a huge scale. Moore averred, “I am surprised at the range of products displayed at this Expo. Some of these products are really good & competitive, which need to be promoted in the European market as well. My message to the exhibitors would be that this is a professional show and you need to take this level of professionalism into your manufacturing plants as well. An event like Engineering Expo is a first step for taking the industry to the next level. The exhibitors should not only focus on India but the world market as well.” During the inaugural session, an exhibitor directory featuring the list of all the exhibitors of Engineering Expo

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Ahmedabad 2012 was also unveiled.

GUJARAT AS A MANUFACTURING HUB The manufacturing industry in Gujarat has highly evolved over the years. Commenting on the growth of manufacturing sector in the state and the importance of Engineering Expo, Swain said, “Manufacturing is one of the core sectors in Gujarat. The State Government has launched ambitious projects for the sector as the objective is to enhance the growth of the industry. In such a scenario, an event like this can add to the growth of the manufacturing segment as

Highlights of this edition 225 exhibitors pan India 15,190+ business visitors Business transacted worth

`60.70 crore 13,136 business leads generated

15,000+ products displayed More than 1,00,000 kg machinery moved in for display

ENGINEERING EXPO AHMEDABAD 2012

it focusses a lot on the small and medium enterprises. The event is a good platform for promoting business, branding and trading. It has really grown bigger since last few years and is a one-of-its-kind Expo.”

BRINGING SMEs INTO LIMELIGHT The distinguished guests saw this mega trade show as an encouraging initiative from the industry’s point of view. Being the largest SME gathering in the state, the Expo has really helped SMEs immensely. Shah noted, “SMEs in the manufacturing segment have limited resources. So, if they want to travel to different places for gathering knowledge about different products, it would not be feasible for them. Thus, in such a scenario, an event where a cross-section of machinery is displayed under one roof can truly benefit the SMEs. They can not only gather knowledge about different products but also have physical access to the various products and technologies. Thus, such events can really aid the growth of industry.”

Manufacturing Industries Ltd, said, “Though such exhibitions do not generate immediate revenues, these surely help a company in the long run as there is ‘word of mouth’ publicity. Moreover, events like these help us to tap customers who are not from the city where we have our office.” Highlighting the long-term fruitful association with the organisers, Bijal Shah, Director, Sharad Industrial Products Pvt Ltd, said, “We have been participating in the Engineering Expo since last three years. Over the years, the event has become highly professional. The Panel Discussion organised as a prelude to the Expo further increased the credibility of this event.” There was a general consensus that Engineering Expo has highly evolved over the years and becoming better with each edition. Major Amitava Mittra, Chief Operating Officer, BGI Engitech Pvt Ltd, said, “The event seems to be a great success. The organisers have put in great efforts to provide us everything we wanted and

VALUABLE EXPERIENCE FOR EXHIBITORS Being an all-inclusive engineering show, the event provided an opportunity to exhibitors from various sectors to spread awareness about their products and services. Bhavin Siddhapura, Chairman, Macht Exim Visitors thronging the stalls at the event LLP, noted, “We first on time. I heartily congratulate the participated in 2010 and since then organisers for putting up such a great we are regular exhibitors in different show.” editions of Engineering Expo, irrespective of the city in which it is held. It has helped us in brand building DISPLAYING A SENSE OF and spreading awareness about our CONTENTMENT products, leading to a good number of The event attracted several visitors business enquiries.” from leading industrial centres in and The exhibitors received an around Gujarat. Their satisfaction with overwhelming response and generated the show can be gauged from the fact many leads with potential to generate that most of them are eagerly looking revenues. S J Gijare, General Managerforward to the next year’s edition. Handling Equipment Division, CTR Ashish Shah, Senior Marketing

Manager (Materials), InspirOn Engineering Pvt Ltd, opined, “I have attended previous year’s Engineering Expo as well, and every year, the event has helped us in locating at least four to five suppliers. We would like to attend this event in the future too as such exhibitions really enhance our knowledge about the industry.” Engineering Expo provided a common networking platform for leaders in the industry to showcase their products and this helped the potential customers in taking better business decisions. “Engineering Expo helps us gather information about the various products available in the market. We are able to interact with several companies at one time under the same roof. This event has really helped in the growth of my business,” noted Vijay Patel, Marketing Manager, Prism Group of Company. Another visitor, Dr B S Munjal, Head, Structural & Thermal Analysis Division, Scientist/Engineer - SG Space Application Centre, Indian Space Research Organisation, said, “This Expo has helped us in widening our technical horizons and gathering maximum information about the products we require.” It is not only the organisers and exhibitors who believed that the event has evolved over the time but even regular visitors shared the same sentiment. Satish Prajapati, Proprietor, Conquest Engineering, averred, “What lures us to Engineering Expo is the brand image of Network 18. It really provides an impetus to the event. Every year, the event is getting better than what it was in the last season.” Taking the next leap forward, the upcoming editions of this multilocation trade show are gearing up to offer the best business prospects to one and all. Don’t miss the opportunity! avani.jain@network18publishing.com

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PANEL DISCUSSION: GUJARAT

Flying high with successful strategies After proving its mettle as an industrial hub on the domestic front, Gujarat is emerging as a much sought after investment destination on the global map. In this backdrop, Network 18 Publishing (a part of Network 18 Group) organised an electrifying strategy meet and panel discussion in Ahmedabad on September 28, 2012, as a prelude to Engineering Expo Ahmedabad, which generated impressive industry response. AVANI JAIN

etwork 18 Publishing (a part of Network 18 Group) organised an electrifying strategy meet and panel discussion on ‘Gujarat: Poised for a Strategic Shift from Share Taker to Market Maker’ in Ahmedabad on September 28, 2012. The aim of this meet was to discuss the industry prospects and challenges faced as well as suggest some action points to position the state as a truly global destination. This panel discussion was a prelude to the largest SME gathering in the country, Engineering Expo. The panelists, an eclectic mix of experts representing government, industry and academia, included Maheshwar Sahu, Principal Secretary – Industries & Mines, Government of Gujarat; Mahendra Singh Dhakad, Programme Director, United Nations Industrial Development OrganisationInternational Centre for Advancement of Manufacturing Technology (UNIDO-ICAMT); Dr Bakul Dholakia, Director, Adani Institute of Infrastructure Management & Advisor, Adani Group; PK Jha, Zonal GM, National Small Industries Corporation (NSIC); Harit Soni, Director, Ecolibrium Energy; Mehul Pandya, Sr VP & Head, SME, CARE Ratings, and Sunil Shah, Chairman,

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The aim of the panel discussion was to discuss the industry prospects and challenges faced as well as to suggest some action points to position Gujarat as a truly global destination

Gujarat Innovation Society. In his inaugural address, Sahu said, “In order to accelerate its growth prospects, Gujarat needs to be developed as a knowledge economy, which means that there should be increased focus on appreciation of knowledge and value addition. Also, efforts should be made by the industries as well as the government to develop Gujarat as a global sourcing hub. The industries need to focus on sustainable and inclusive growth avenues as it can define new horizons for further comprehensive economic development. Constant innovations and skilled manpower availability are other issues that need attention.” Gujarat being a proven starting base for Micro, Small and Medium Enterprises (MSMEs), the industry experts elaborated on the steps to be taken by them to enhance growth prospects. Dhakad observed, “There needs to be adequate steps taken to accelerate the growth of MSMEs and make them partners in progress. They have remained MSMEs for generations. So, they need to change their attitude and leapfrog to a higher level. Also, they should come forward and take adequate steps to develop R&D centres to accelerate

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innovations.” Talking about the steps to be taken by the governing bodies and institutions for the development of MSMEs in the State, Dr Dholakia said, “There needs to be an institutionalised framework for industries with adequate exposure to the latest technologies and business practices available internationally. Above all, one of the unique features of the industrial climate of Gujarat is that neither the government nor the industrialists ask what the government is doing for them, but they believe in making the best from what is available to them.” Adding perspective to the discussion, Shah said, “First of all, the mindset needs to be changed. It starts with referring to MSMEs as emerging enterprises and not tagged as ‘MSMEs’ forever. Moreover, greater emphasis should be on skilled manpower development as it is one of the primary needs of the industry in the current scenario.” The panel discussion was followed by a Q&A session. This was moderated by Archana Tiwari-Nayudu, Executive Editor, SEARCH, Network 18 Publishing. The success of this event can be clearly gauged from the fact that more than 200 people attended this lively panel discussion.

ENGINEERING EXPO PUNE 2012

PUNE November 2-5, 2012 Auto Cluster Exhibition Centre

Facilitating business on a

Higher Plane Mahratta Chamber of Commerce, Industries & Agriculture (MCCIA) forecasts that Pune region alone will ring in investments in the auto industry to the tune of `40,000 crore during 2008–13. It indicates the emerging opportunities for this industry and allied sectors. And Engineering Expo Pune edition, organised by Network 18 Publishing, is gearing up to facilitate business leads between vendors, suppliers and eminent buyers in the manufacturing and process industries. Auto Cluster Exhibition Centre, Pimpri, is all set to witness the action during November 2–5, 2012. A report... MAHUA ROY

une once had the reputation of being a pensioner’s paradise. However, the recent spurt in investments has completely transformed the city into a lively metropolis. In recent years, along with IT investments by reputed companies, it has also attracted huge investments in auto OEMs and ancillary industries. The industrial clusters of Chakan, Pimpri-Chinchwad and Talegaon can be called the ‘Detroit of India’. Companies such as Tata Motors, Bajaj Auto, Volkswagen, General Motors and Force Motors are boosting the growth of ancillary units in these areas, thus creating a bustling investment destination.

PROMISING PUNE According to Debajit Roy, Assistant Manager – Marketing, South Asia, Kohler Co, “Pune is strategically located close to the financial capital, Mumbai. The auto industry has been flourishing in this region. Not only this, the entire industrial hub around Pune has seen multinationals from various sectors setting up their base here to leverage on the Small & Medium Enterprises (SME) advantage.” In recent times, a large number of friendly developmental policies and initiatives

from the governmental bodies have resulted in the emergence of Pune as a preferred choice for the process and manufacturing sector to have a firm presence in this region. The last decade has witnessed a substantial growth in the SME sector, with numerous units springing up and adopting the latest manufacturing technologies. This is where Engineering Expo brings in its expertise of uniting the SME sector with prospective clients. This provides a holistic businessgeneration experience. Engineering Expo has been a supportive partner to the facilitation of business deals in a big way in the Pune industrial cluster.

ADVANTAGE ENGINEERING EXPO Year 2012 marks the seventh edition of Engineering Expo Pune. These years have seen a steady growth in the number of exhibitors and visitors. Elaborating on the legacy of Engineering Expo, Sandeep Khosla, CEO, Network 18 Publishing, says, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multi-location trade show on manufacturing. The Expo is a preferred destination for SMEs as well as manufacturing & engineering organisations to further their growth and that of the industry at large. For the 2012–13 season, we have eight editions spread across an equal number

Glimpses of previous edition Highlights of this edition

250+ exhibitors 12,894+ visitors 5,000+ products displayed

250+ expected exhibitors 17,000+ business visitors

`81 crore business generated 45,000 sqm exhibition area 1,00,000 kg machinery moved

8,834 business leads generated

expected Business transactions worth `85 crore expected 10,000+ products on display Spread over an area of more than 3,500 sq m Showcasing more than 30 diverse industry categories

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ENGINEERING EXPO PUNE 2012

Asia and SKF India. of locations of a rising India. Keeping NEW ATTRACTIONS our esteemed exhibitors and valued IN THIS EDITION customers in mind, we have made THE PERFECT LAUNCH PAD elaborate provisions to offer a neverThe previous editions of Engineering Panel discussion aims at before experience. These, we reckon, Expo have been treated as a launch providing a road map to infuse will add substantial traction to the pad for the introduction of new growth in the region Institutional Buyer Involvement industrial growth of the nation.” solutions and technologies for the Plan to attract delegations from Besides, Engineering Expo has manufacturing & process industries. large corporate and major captured a large exhibitor base that Exhibitors are using all kinds of institutions has stayed loyal towards the brand, strategies and promotional initiatives Improvised visitor profiling thereby exhibiting year after year. G to create an ideal scenario for a —profile, scan, filter and bring in Ganesan, Manager – Sales, Guindy product launch this year as well. For visitors as per exhibitors’ Machine Tools Ltd, notes, “This is the instance, Guindy Machine Tools will requirements second time that we are participating be utilising the Pune Engineering Providing business networking in Engineering Expo Pune. What Expo platform to showcase its range of support to exhibitors by is unique about this platform is the co-ordinate measuring machines. “This leveraging Network 18 presence of focussed visitors. This has product is of prime importance to the Publishing’s industry connect helped us generate critical leads to our automobile and heavy engineering Credit rating facilities for the benefit of exhibitors businesses and garner good response sector. Engineering Expo will be the Providing complete travel over the years. We have had one of the perfect platform for us to reach out solutions for exhibitors best experiences with the organisers.” to the audience. The Expo has been Offering logistics services to Engineering Expo Pune will be attracting quality visitors. Thus, this ensure smooth cargo handling, held at a right time in the calendar enables us to reach a focussed base of custom clearing, transport year, which makes it a favourite prospective customers and generate a compliance, etc. destination for exhibitors and visitors high volume of business leads,” adds alike. CM Venkateshwaran, COO, Ganesan. Aker Powergas Subsea Pvt Ltd, the Expo is a platform to discuss and The layout of the Engineering and Past Chairman, Process Plant take stock of the latest trends in the Expo enables exhibitors to showcase and Machinery Association of India manufacturing industry. Commenting their product portfolio in an aesthetic (PPMAI), explains, “The timing of on the same, Anant Chind, manner, also making provisions for live the Engineering Expo could not have Executive Director, Chind Iron and demonstrations. Such an interactive been better. As it is held towards the Steel Industries Ltd and a visitor in forum provides exhibiting companies end of the year when companies take a the 2011 season of Engineering Expo an opportunity to attractively display stock of what they have done over the Pune, expresses, “Engineering Expo their products. Reni Emmanuel, year, it is the time when companies has grown rapidly over the years. It CEO, Emmaus Mac, elaborates, “We try to foresee what the future holds. has become more demanding with specialise in pattern making and serve The timing, the growth-oriented the number of exhibitors increasing the ancillary units or vendors to the economy and the platform every year. We are into organised by Engineering sheet metal working and Engineering Expo brings in its expertise of uniting the SME Expo makes a winning machine tools industry sector with prospective clients. This provides a holistic business-generation experience. combination.” and consider this event The 2011 edition of as the best platform to Engineering Expo Pune recorded gain further know-how of the current automobile industry in particular. This business transactions worth `81.10 industry scenario.” is one of the prime reasons we chose to crore, with more than 8,834 business exhibit in Engineering Expo Pune due Offering an ideal interactive leads generated, as per the feedback to its strategic location. We hope to see platform, Engineering Expo received from the exhibitors. Around a large number of visitors, which means provides Indian companies an 5,000 products from various industries serious business. We will be displaying excellent opportunity to explore new were on display in an area spanning our expertise in customisation of technologies, which will help local 45,000 sqft. It saw visitor delegations patterns and reverse engineering.” manufacturers meet global standards. from eminent companies such as Tata So, do not miss this opportunity and Motors, Aker Powergas, Mahindra & be there to make the most of it. ‘EXPO’NENTIAL GROWTH Mahindra, Bajaj Auto, Bosch, Forbes Apart from providing a conducive Marshall, Messung, Thermax, Sandvik business environment for business leads, mahua.roy@network18publishing.com

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ENGINEERING EXPO CHENNAI 2012

CHENNAI November 22-25, 2012 Chennai Trade Centre

Offering a competitive advantage With the passage of time, Chennai has emerged as a hub for the automotive and allied industries. Amid this as well as the growth of other industries, Network18 Publishing is all set to hold the ﬁfth edition of Engineering Expo Chennai. This edition will provide a suitable platform to exhibitors for showcasing their products and services to prospective visitors in a competitive atmosphere. Set to be held during November 22-25, 2012, this edition endeavours to get bigger and better. SHIBANI SHAH AND CHANDREYEE BHAUMIK

hennai, originally known as Madras, has always been a major industrial hub. Located on the Coromandal Coast of the Bay of Bengal, the city is well connected to different parts of the country. With a number of industries located in Chennai the industrial growth of the city is at par with other parts of the globe. According to Deepak Sharma, Partner, Ball & Roller Bearing Co, “Chennai, in the past few years, has grown to become the largest automobile manufacturing hub and is still growing; in a single word Chennai has become a one-stop solution for industries.”

EVOLVING INDUSTRIAL DESTINATION Vision 2026 is to make Chennai a prime metropolis that will be more liveable, economically vibrant and environmentally sustainable as well as with better assets for future generations. According to various industry reports, the manufacturing industry of Chennai comprises large segments ranging from petrochemicals and chemical industry, electrical and automobile and several other related ancillary industries. Some of the largest industrial areas such as Ambattur and Manali are located in Chennai Metropolitan Area (CMA) and house multi-product industries. Other industrial estates at Guindy, Thirumazhisai and Thirumudivakkam house medium and small-scale

industries. Chennai has a large base of leather industry and accounts for about 50% of the total exports of the country. Most of the footwear industries are located within CMA. In addition, a cluster of chemical industries is located at Manali in CMA. Further, an exportprocessing zone spreading over an area of 261 acre is located at Tambaram for apparel and other exports. Elaborating further, S Raghavan, Proprietor, Best Systems & Services, expounds, “Chennai is a potential industrial city. As major international companies are setting up shop here, the supportive and ancillary industry growth is imminent. Chennai is developing proper infrastructure and promoting new industrial areas, which attracts a lot of investors. Chennaites’ work culture is also conducive to the new industries—both foreign as well as domestic.” Highlighting why Chennai has become an attractive destination,

Highlights of this edition 200+ expected exhibitors 15,000+ expected visitors Business transaction worth `48 crore expected 8,000 + products on display Spread over an area of more than 4,200 sq m Showcasing more than 30 diverse industry categories

K Ravi, GM, MGM Varvel Power Transmissions, elaborates, “Chennai is an attractive destination because of its infrastructure, the port and the established manufacturing base, and because of its desire to grow more.” Large automobile engineering, glass and ceramic industries, are located at Maraimalai Nagar, Irungattukottai, Sriperumbudur, Thiruvallur and Gummidipoondi around Chennai. It is interesting to note that Tamil Nadu accounts for about 21% of passenger cars, 33% of commercial vehicles

Glimpses of previous edition 175 exhibitors 11,359 business visitors 5,000+ products displayed

`41.98 crore business generated

4,200 sq m exhibition area 85,000 kg machinery moved Delegations from more than 84 different companies such as Apollo Tyres; Brakes India; Bharath Weld Equipments & System; Bureau Vertas India; Valeo Systems; Petro Constructions; Lucas TVS; Wabco TVs; RK Engg Works; Indian Navy; Hyundai; Larsen & Turbo; Michellin Tyres; Foxconn India and many more

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ENGINEERING EXPO CHENNAI 2012

and 35% of automobile components produced in India. Indeed, Chennai, the ‘Detroit of India’ is truly emerging as a major export hub for cars in South East Asia. Commenting on the scope Chennai provides, PK Sivaswami, Mentor, India Operations, Zhejiang Fit Bearing Co Ltd, avers, “Chennai is a major hub for manufacturing auto components, electric motors, two wheelers, etc. This scale of exposure to the industry by participating in such events will help us to develop a market for our brand of bearings, which are at par in terms of quality with leading manufacturers offering competitive pricing.”

NEW ATTRACTIONS IN THIS EDITION Panel discussion aims at providing a roadmap to infuse growth in the region Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions Improvised visitor profiling —profile, scan, filter and bring in visitors as per exhibitors’ requirements Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect Credit rating facilities for the benefit of exhibitors Providing complete travel solutions for exhibitors Offering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc

GLORIOUS PAST EDITION The 4th edition of Engineering Expo Chennai in 2011 offered a unique platform for the exhibitors to showcase their products and business enhancement. There were more than 5,000 products displayed and about 12,692 visitors and generated a business transaction worth `41.98 crore. Apart from showcasing the best in terms of engineering innovations and technologies, the 4th edition of Engineering Expo Chennai 2011, served as a conducive platform in amalgamating the capabilities of the state with specific needs of the industries. With a strong base in MSME, this exhibition offered a unique advantage by not only providing new opportunities for enhancing the business, but also for augmenting the existing process with cost-effective technologies. Being an all-inclusive engineering show, the event provided an opportunity to exhibitors from various sectors to spread awareness about their products and services. Describing the reason for his participation, Raghavan adds, “We were inspired by the visitors’ profile and response to the expo.” With the expo expected to get bigger and better this year, the organisers are looking forward to larger number of exhibitors and visitors. Elaborating

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further, Ravi adds, “Our experience last year was good and we are looking forward to get more prospects this year.”

FROM THE ORGANISER’S DESK Engineering Expo turns 11 this year. Elaborating on the success graph, Sandeep Khosla, CEO, Network 18 Publishing, comments, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multilocation trade show on manufacturing. The Expo is a preferred destination for small and medium enterprises as well as manufacturing & engineering organisations to further their growth and that of the industry at large.” “For the 2012–13 season, we have eight editions spread across an equal number of locations of a rising India. Keeping our esteemed exhibitors and valued customers in mind, we have made elaborate provisions to offer a never before experience. These, we reckon, will add substantial traction to the industrial growth of the nation,”

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Khosla adds.

EXPECTATIONS FROM EXHIBITORS With the Engineering Expo Chennai 2012 on the anvil, it is time for the exhibitors to build up on their expectations. Discussing his expectations from the expo, Sharma states, “We are expecting a huge footfall from quality buyers. We look forward to spreading awareness about the availability of world-class quality products and generating new possibilities of developments in products & services.” While exposure to potential clients and quality visitors is the major expectation of the exhibitors, Raghavan adds, “We want to exhibit our potential in providing innovative solutions to typical requirements of process industries.” Continuing in this regard, Manoj Kumar, Director, Apex Auctions India Pvt Ltd, informs, “We are sellers of equipment, machine and tools pertaining to the manufacturing industry and are participating in the Engineering Expo Chennai for the first time. We are expecting the right to gain exposure to the small and medium enterprises, small scale industries who will be attending the expo.” Seconding the above thoughts, K Balaji, CEO, Aquaflow Enterprises, elaborates, “We are hoping to generate enquiries. Last year, we had participated in the expo and this is the second time for us. This expo is beneficial for us since Chennai is the manufacturing hub, and therefore, we are aiming to generate a lot of business from here.” Sharing his expectations, Ravi adds, “We are anticipating visitors from sectors such as auto, pharma, chemical, automation, material handling, construction and packaging to visit us. We are focussing on our range of products such as gearboxes, gear motors, motors & brake motors, and are aiming to establish our brand.” shibani.shah@network18publishing.com chandreyee.bhaumik@network18publsihng.com

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PRODUCT INDEX Looking For A Specific Product? Searching and sourcing products were never so easy. Just type SRCH (space) Product Name and send it to 51818

eg. SRCH Pump and send it to 51818 Product

Pg No

2500 AMP ACB PANEL 163 AC gear motor 6 AC motor 55, fgf AC servo motor 6 AC variable frequency drives 18 Accessories 8 Acoustic enclosure 119 Actuators 162 Adaptor 181 Adaptors for drilling 203 Agitator seals 66 Air operated diaphragm pumps 142 All gear lathe 162 All geared auto feed pillar drilling machine 173 All geared drilling cum milling machine 199 All geared head 199 Alloy steel cold drawn seamless straight tubes/pipes 183 Alu-cera polymer 7 Aluminium bronze 185 Aluminium casting 161 Aluminium oxide ceramic composite 7 Aluminum 183 Aluminum extrusion 160 Analog timers 27 Angle measuring instrument 140 Annunciator 71 Auto belts and oils seal 17 Auto feed radial drilling machine 173 Auto power feed 199 Automatic rolling shutter 19 Automation 20 Automation systems 91 Automotive automation 79 Autophoretic coating 150 Axial flow fans 169, 183 Back fill compound 125 Balances 133 Ball bearing 16, 109, 175 Ball check valve 177 Ball screws 16, 149 Ball valve 177, 178 Battery operated pallet trucks 121 Bearing 16, 24, 139, 140, 175 Bellow couplings 149 Belt conveyor and gravity roller 153 Bench grinder 140 Benchtop presses 141 Bend 103, 178 Beryllium copper plastic mould materials FIC Blackening / bluing salt 150 Blowers 151 Blowers & Fans 169 Boiler compound & scale remover 150

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Product

Pg No

Booster pumps 184 Bop drills 154 Bottle cap torque testing systems 67 Bottle filling machine 154 Brake motor 55, 84, 165, FGF Brass accessories for switches 113 Brass building hardware 113 Brass cable glands 113 Brass components 113 Brass electrical wiring accessories 113 Brass extrusion rods 113 Brass indian cable glands & accessories 113 Brass neutral 113 Broaching machines 61 Building automation 20 Busbar components 164 Busbar system 164 Bushes 16 Butterfly valve 177, 178, 183 Cable carrier 24, 149 Cable clamp 180 Cable conduits 21 Cable connector 24 Cable gland 51, 99, 145, 179, 180 Cable marker 180 Cable tie 180 Cam followers 141, 172 Camworks 160 Capacitance & tan delta testers 157 Carbide 181 Carbide tools 181 Carbon steel cold drawn seamless straight tubes/pipes 183 Carrier oil 181 Cast/extruded 161 Castings 161 Castors 155 Cathodic electrocoating 146 Cbm/pdm services 170 Centralised lubrication system 163 Centre drill 181 Centreless grinding machine 171 Centrifugal air blowers 169 Centrifugal fans 211 Centrifugal pumps 39 Chain 17, 24 Chain pulley block 146, 165 Chemical earthing 125 Chemical resistant diaphragm vacuum pump 154 Chemical tanks 184 Chemrode reslow 125 Chiller 166 Chromatsing chemicals 150

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Product

Pg No

Chuck 181 Circuit breaker analyzer 157 Cleaning equipment 201 CNC .bic CNC cutting machines 20 CNC cylindrical external grinding machine 171 CNC external grinding machine 171 CNC hydraulic turret punch press 159, 185 CNC internal grinding machine 171 CNC laser cutting machines 20 CNC lathes 23 CNC machines .bic CNC oxy fuel cutting machine 20 CNC plasma cutting machine 20, 159, 185 CNC press brak 159, 185 CNC synchro press brake 159, 185 CNC tap chucks & tap adaptors 203 CNC tap holders & pull studs 203 CNC toolings 181 CNC tools holders & pully studs 203 CNC turning center .bic CNC vertical machining center .bic Coating 150 Coating machines 20 Coating plants 20 Coating systems 20 Coating thickness gauges 149 Cold galvan 150 Collet 181 Collet chuck 181 Componet handing system 79 Compressed air division 169 Compressors 169 Concrete energy savings 41 Connector 8, 14, 24, 77 Container pumps 142 Containers 184 Contrast/colour scanner 97 Control cabinet 77 Control damper 162 Control panel 77 Control system 77 Controls 141 Conventional and mono block pump 143 Conventional phase failure relays 27 Conventional precision lathes 23 Conveying blower 169 Conveyor 155 Conveyors and automation systems 19 Coolant accessory 143 Coolant pump 143, 149 Coolant separator 149 Cooling systems 101 Cooper chromium zirconnium 185

PRODUCT INDEX Product

Pg No

Copper bonded rod 125 Copper chromium 185 Copper enamelled wire 154 Counter 27, 71 Crab hoist 165 Crabs 146 C-rail festoon system 164 Crane 102, 146, 165 Crane busbar 164 Crane duty motor 84, 120, 165 Crimp testers 67 Cross connection acc 8 Crrosin inhibitors 150 Current collector 164 Current injectors 157 Cushion dock shelters 19 Custom mouldings 184 Cutting fluid 150 Cutting machines 20 Cutting oils.water soluble tapping oil 181 Cutting valves 154 Cylindrical grinding machine 175 Cylindrical photoelectric sensor 155 Cylindrical roller bearings 139 Cylindrical sensors 97 Dampers 162 Dampers for centr 183 Data acquisition systems 179

Product

Pg No

DC motor 55, FGF Dehumidifiers 167 Demagnetiser 184 Deoxidized copper 185 Dereasing / cleaning agents 150 Designable trollies 164 Dfmpro 160 Diamond disc 141 Diaphragm valve 177, 178 Didactic equipment for training 77 Digital temperature controller 176 Dip-pipes 177 Distrubution board 10 Dock levellers 19 Dock shelters 19 Donor chair 157 Door - pvc flap 19 Door - pvc strip 19 Door - rapid flexible 19 Door - rapid roll up 19 Door - sectional overhead 19 Door â&#x20AC;&#x201C; telescopic 19 Double drum & triple drum magnetic separetor 184 Double sheet monitoring 97 Drawer magnets 184 Drill chuck arbor 181 Drill chucks 169

Product

Pg No

Drill mill 181 Drilling machine 173, 199 Drilling units 158 Drills 173 Drives 176 Drum pumps 142 Drum type magnetics seperator 147 Drums & carboys 184 Dry van pump 119 Dryers 26 Dual channel with modbus 176 Dynamic controller 176 Earth & fuse bars 113 Earth rods 125 Earthing 125 Edm oil 181 Edrawings publisher 160 Elbows 177 Electric belt hoist 158 Electric wire rope hoist 165, 174 Electrical discharge machining oil 150 Electrical product 18, 51, 99, 145, 179 Electro mechanical servo systems 141 Electroless nickel plating 150 Electrolizer assemblies 164 Electronic etching pencil 174 Electronic process controls instruments 145 Electronic safety sensors 160

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PRODUCT INDEX

Product

Pg No

Electronic test 157 Electronic timer 28-35, 71 Electronica india 2012 73 Electronics fair 73 Electronics product 51, 99, 145, 179 Electropnematic positioner 143 Element shrink disc 172 Encon products 170 End cap 178 End clap/shop 8 End mills 181 End plate 8 Energy efficiency solutions 41 Energy meter 71 Energy savings cogged & poly-v- belt drive 17 Engineering plastic plug & socket 28-35 Enginnering plastics 161 Eot crane 165, 174 Eot jib crane 102 Eot/hot cranes 146 Ese lightning arrester 125 Evaporator 26 Exhausters 151 Exhibition 73 Exhibition - automach 2013 144 Exhibition - engineering expo 137, 187 Exhibition - vcci 2013 168 Expansion bellows 177 Factory automation 20 Fail safe assembly system & consumer automation 79 Fbe & nylon coating 150 Ferrous / Non-ferrous casting 160 Fiber laser 142 Fibre optic amplifier 97 Filter cock 178 Filtration 133 Fire rolling shutters/ fire doors 160 Fire sliding door 140 Flame proof hoist 146 Flame proof motor 55, 84, FGF Flange mounting motor 55, FGF Flanges 180 Flash dryer 26 Flat high tension single-twin ignit 7 Floating holders 203 Flow indicator 178 Flow meters 133, 142 Fluid 22 Fluid handling 133 Fluid processor 153 Flush bottom valve 177 Fmcg & auto comp 79 Food-grade lubricants 180 Foot valve 178 Force 67 Force & pressure calibration & testing equipment 67 Force & torque gauges 67

200

Product

Pg No

Force feed lubricator 142 Forged components 160 Forging 8 Forked photoelectric sensors 97 Freewheel-oneway-clutches 172 Frp underground fuel tanks 184 Fuel burners 169 Fuel pump 161 Furnace automation 48 Furnace oil flow heater 151 Gantry crane 102, 165 Gear boxes 22, 84, 146, 174 Geared & flexible couplings 22 Geared drilling machine 199 Geared head lathe machine 142 Geared motor 22, 55, 165, 174, FGF Gears 22 Gel earthing 125 Geomcaliper 160 Glide wheels 155 Gluing systems 129 Goliath crane 146, 165 Goliath cranes 162 Gomet bearings 109 Goods lift 102, 146 Graded grey iron castings 213 Gravity die castings 161 Grinders 171 Grinding machine 171, 175 Grinding media 7 Gudgen pins 139 Hand roll marking m/c 207 Handheld thermal imaging camera 184 Hanger clamp pole 164 Hanlding system module 77 Hard chorme plating 150 Heat resistance coating 150 Heat shrink tubing 51, 99, 145, 179 Heat transfer equipments 211 Heat treatment salt 150 Heater power controller 162 Heating 91 Heating element 178 Heating solutions. 117 Heavy duty CNC 179 Heavy duty cyling duical bearing 109 Heavy duty forged steel castor 153 Heavy duty lathe machine 162, 175, 182 Heavy duty ttr castor 153 Helical gear box 84, 174 Helical geared motor 84 High alumina wear resistant ceramic tiles 7 High discharge (flooding type ) pump 143 High efficiency standard motors flame proof motors 120 High intensity rare earth magnetic seperator 147 High intesity roller type magnetic seperator 147

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Product

Pg No

High pressure blowers 211 Hipots (high voltage testers) 157 Hold back 172 Hopper magnets 184 Horizontal CNC machines .BIC Horizontal machining center .BIC Horizontal spindle rotary table surface grinder 171 Hosphating chemicals 150 Hot forging lubricants 181 Human machine interface 18 Hump magnet 184 Hydraulic cylinders 61 Hydraulic cylindrical grinding machine 171 Hydraulic equipments 61 Hydraulic forging hammer 128 Hydraulic handlift pallet truck 182 Hydraulic manual pallet trucks 121 Hydraulic power packs 61 Hydraulic press brake 159, 185 Hydraulic presses 61, 128 Hydraulic seals 87 Hydraulic shearing machine 159, 162, 185 Hydro pneumatic presses 207 I/p transducers 143 Imaging & vision systems 20 Impeller 178 Imtma - productivity buzz 156 Inductive proximity switches 21 Inductive switches 97 Industrial automation products 18 Industrial belt 17 Industrial bolt 164 Industrial castings 213 Industrial ceramic 7 Industrial electric power distribution system 10 Industrial ethernet switch 46 Industrial fans & blowers 183 Industrial heating element 178 Industrial hose 17 Industrial pumps 148 Industrial valves 160 Inline drum type magnetic seperator 147 Inline helical geared motors 120 Instro mentatin controls pannels 145 Instrumentation & control 12-13 Insulated boxes 184 Insulating oil tester 157 Insulation resistance testers 157 Integrated solutions 207 Intelligent power factor controller 185 Interface modules 8 Interface modules acc 8 Inverter duty motors 120 Isolator 83 Jib crane 146, 145 Kamlok & drylok couplings 148 Keyless transmisson element 172

PRODUCT INDEX

Product

Pg No

Knife gate valves 183 Laboratory supplies 133 Large diameter welded pipes 163 Large helical 120 Laser cutting 103 Laser marking systems 207 Lathe machine 162, 175 LED 21 LED signal tower light 28-35 Lifting magnets 184 Light duty lathe machine 175 Lightning arrester 125 Lightning consultants 125 Lightning protection system 125 Limit switch 28-35, 143 Liquid ceramic coating 150 Liquid pumps 142 Liquid ring vacuum pump 169 LM guide ways 149 Load break switches 21 Loading arms 148 Long neck pipe end 178 Low pressure die casting 161 Machine tool 48 Machine tool accessories 149, 203 Machine tools castings 213 Machined components 160 Magnaled sphere 164 Magnetic coolant seperator 147 Magnetic pulley 184 Magnetic racks 184 Main & sub-system assembly automation 79 Marker plotter 8 Markers 8 Material handling 48 Material handling containers 184 Material handling equipment 121, 165 MCB 83 Measuring instruments 157 Measuring sensors 97 Mechanical press brake 159, 185 Mechanical seals 66 Mechanical seals for process equipments 66 Mechanical vacuum boosters 151 Media and entertainment company 152 Medium duty lathe machine 162 Medium duty lathe machine 175 Metal cleaners 181 Metal cutting tool 5 Metal-forming lubricant 153 Metallic conveyor belt 180 Mgm brake motor 47 Micro switch 28-35 Mill lining blocks 7 Mini sensors 97 Mixers 133 Monitoring 141 Monorail trolley 146 Motion control 129

202

Product

Pg No

Motor 55, 84, FGF Motor protection circuit breaker 21 Motor protection relay 166 Motor testing systems 67 Motorised vibrating screen 167 Motorised chain pulley block 146 Motors & control 61 Mounting bracket 8 Multi-flute thread mills 167 Multistage (high pressure ) pump 143 Multistage centrifugal air blowers 169 Munting rails 8 Needle bearings 139 Needle roller bearing 16, 109 Network sensor 181 Nickel silver 185 Non return valve 178 Non-ferrous castings 161 Nozzles 148 Numerators. 207 O rings 87 Oil 169 Oil cooler 166 Oilseals 164 Over band magnetic seperator 147 Over crank shearing machine 159, 185 Oxy fuel cutting 159, 185 Paint remver 150 Paint strippers 181 Painting 91 Pakaging paper pulp 48 Pallets 184 Panel bender 103 Panel bender & material handling 103 Panel cooler 166 Panel meters 27 Parallel shaft heical geared motors 120 Partition plate 8 Pedestrian & rider operated counter balanced pallet trucks 121 Permanent magnetic chucks 184 Permanent magnetic drum pully 147 Permanent magnetic drum type separator 184 Phase failure relays 27 Phase monitoring device 71 Phosphorus bronze 185 Pid controlers 145, 176 Pillar drilling cum milling machine 199 Pillar drilling machine 173 Pilot lights 21 Pin marking systems 207 Pipe joints clamp system 153 Planetary gear head 149 Planning machines 179 Plano milling machines 179 Plat truck 155 Plate bending machine 159, 179, 185 Platemagnets 184

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Product

Pg No

PLC 176 Plug valve 177 Plugs and sockets 21 Pneumohydraulic 141 Pole ring 178 Polishing films 146 Polyacetal 161 Polypropylene 161 Polypropylene pickling tank 167 Polyurethane 161 Power 141 Power magnet 184 Power operated hydraulic press 143 Power press 159, 185 Power systems 101 Power transmission accessories 17 Pratective polymer coating 150 Precision lock nuts 149 Precision switches single & multiple 21 Pressed steel castor 153 Presses 141 Pressure sensors and indicators 67 Printing 48 Process automation 129 Process automation and cntrol equipment 77 Process gas blowers 211 Product assemblies. 160 Product index catalogue 133 Productronica india 2012 73 Productvity station 46 Profile controller 176 Proximity sensor 28-35 PTFE 150 PTFE lined piping 177 PTFE lined systems 177 PTFE/teflcon 161 Pull stud 181 Pump castings 213 Pump seals 66 Pumps 39, 61, 199, 133, 142, 169, 211, BC Punching 103 Punching-shearing system 103 Push buttons 21 PVC bus bar system 164 Quick change tapping chucks 203 Race pins 139 Radail drilling machine 173, 199 RCCB 83 Reach lift truck 182 Reamers 181 Reaming & tapping 203 Receptacles 148 Reducer 177, 178 Relays 27 Re-sharpening solutions 107 Rice rubber roll 17 Robotic machines 170 Roll forming machine 170 Roll markers 207

PRODUCT INDEX

Product

Pg No

Roller bearings 16, 139 Roots blower 119 Rotary air lock valve 170 Rotary atomiser. 26 Rotary dry vacuum 211 Rotary screw compressor 172 Rotary shaft seals 87 Rotary switches 21 Rotary vane oil lubricated vacuum pump 148 Rubber products 164 Rust preventive 150 Rust removers 150 Safety controls 141 Safety protection devices 21 Sampling valve 177 Saw blades 107 Scable ties 51, 99, 145, 179 Scoop 178 Scr bess power regulator 145 Screw presses 128 Seals 164 Seamless pipes 163 Sensor soultions 129 Separator plate 8 Servo drives 18 Servo motors 18 Servo systems 101 Showel 178 Side channel blowers 169 Side lock adaptor 181 Sight flow meters 148 Silence flow packages 211 Silicon brass 185 Silicon bronze 185 Silver copper 185 Singal convrter isolator modules 145 Single limit switches 21 Sleeve bearings 109 Slipon flange 178 Slipring crane duty motor 55, FGF Small size ball bearings 109 SMPS 71 Snu worm gear 22 Sockets & switches 8 Solderless terminal 51, 99, 145, 179 Solid carbide drill 5 Solid carbide drill with IC 5 Solid carbide end mill 172 Solid carbide mill 5 Solid carbide reamer 5 Solid carbide reamer with IC 5 Solid carbide special drill 5 Solid carbide special mill 5 Solid carbide special reamer 5 Soluble cutting oil 148 Space sector 79

204

Product

Pg No

Spade 178 Special applicatin motors 120 Special purpose machines 179 Special tools 181 Spherical bearing 139 Spin flash dryers 26 Spindle motor 173 Spiral cum helical gear box 22 Spray dryers 26 Spray guns 169 Spring testers 67 Stainless steel pipes 163 Steam boiler 173 Steel bars 174 Steel industry 48 Stepping motor drive 174 Super precision bearings 109 Super rigid press 175 Superior hard anodizing 150 Surface grinding machine 175, 176 Surge arrester 125 Surge protection 125 Swing check valve 176, 177 Switch 83 Swivels 148 Tachometer 71 Tap adaptors 203 Taper bearings 139 Technical ceramic 7 Tee 177, 178 Temperature 133 Temperature controller 27, 71, 176 Temperature indicator 27 Temperature sensing 151 Temperature transmitter 151 Tensile testing 67 Tensioner nut 172 Terminal blocks 8 Thermal imaging cameras 65 Thermocouple cables 151 Thermocouple sensor calibration system 151 Thrust ball bearings 109 Tie mount 180 Time switch 71 Timing belts and pulleys 182 Tools 181 Torque 67 Torque measuring flanges 180 Torque motors 120 Torque tool testers 67 Track rollers 172 Trade show 73 Transfer trolley 146 Transformer ratio meters 157 Transformer winding resistance testers 157 Tri lobe roots blowers 151

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Product

Pg No

Tri-lobe rotary blowers 176 Trim handling systems 169 Trolleys 155 Truck blowers 211 Tubes 163 Tubing accessory 77 Turkkit strips & sheets 172 Turned components 160 Turning machine solutions 111 Twin castor. 153 Twin lobe roots blowers 151 Twin spin bearing reducer 149 Twist drills 181 ‘U’ tubes 163 Uhmw-pe 161 Ultrasonic sensors 97 Universal controller 176 Universal quick change chuck 203 Ups systems 178 Vacuum booster pump 119 Vacuum system 119 Valve 77, 162, 177, 178 Valve positioner 143 Valve stem packing 182 Valve terminal 77 Vane damper 169 V-belts 178 Vertical turning lathe 179 Very low frequency hipots 157 Washdown station 163 Washer 178 Waste and water treamnets 48 Water exhibition 155 Water faucet & tap parts 7 Water ring vacuum pump 169 Water softening compound 150 Welded pipes 163 Welding equipments 169 Wheel assembly 174 Wheel barrows 155 Wheel chute and accessories 153 Wheels 153, 155 Wieghing applications 48 Winche 102 Wind mill gear box 22 Wire connector 51, 99, 145, 179 Wire rope drum 174 Wire rope hoist 146 Wireless datalogger system 164 Wiring accessories 180 Worm drive hose clamps 173 Worm gear 22 Worm geared motors 84 Xylan coating 150 ‘Y’ type strainer 177, 178 Zinc flake coating 150 Zirconia polycrystal ceramic 7

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To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@network18publishing.in or call us on +91-22-3003 4653 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

Pg No

Academy For Conservation Of Energy

170

Advertisers’ Name & Contact Details

Pg No

Ashok Industry

150

Advertisers’ Name & Contact Details

Pg No

Bry Air (Asia) Pvt Ltd

167

T: +91-265-2325034

T: +91-22-26232133

T: +91-11-23906777

E: info@syguruace.com

E: manisha@ashokindustry.com

E: bryairmarketing@pahwa.com

W: www.syguruace.com

W: www.ashkindustry.com

W: www.bryair.com

ACME Air Equipment Co Pvt Ltd

151

Atlas Castings Pvt Ltd

T: +91-79-25831985

T: +91-120-2674615

E: info@airequipments.com

E: atlascastings605@gmail.com

213

C&S Electric Ltd.

T: +91-11-30887520-29 W: www.cselectric.co.in

W: www.airequipments.com Allied Electronics Corporation

Atul Machine Tools

T: +91-22 61953699

T: +91-281-2360227

E: allied@vsnl.com,

E: info@atulmachine.com

W: www.aecconnectors.com

W: www.atulmachine.com

Allied Power Solutions

125

Avasarala Technologies Limited

175

Cenlub Systems

163

T: +91-129-4113771 E: sales@cenlub.com W: www.cenlub.com 79

Champkraft Machine Tools

T: +91-09999301007

T: +91-80-26083300

T: +91-2752-241881

E: sm@alliedpowersolutions.com

E: marketing@avasarala.com

E: champ1@sancharnet.in

W: www.alliedpowersolutions.in

W: www.avasarala.com

W: www.solcogrinder.com

Amsak Cranes Private Limited

102

Baumer India Pvt Ltd

129

Classic Polymers & Resins

T: +91-44-26273486

T: +91-20-25286833

T: +91-22-24465251

E: sales@amsakcranes.com

E: mbhalerao@baumer.com

E: sales@classicpolymers.co.in

W: www.amsakcranes.com

W: www.baumer.com

W: www.classicpolymers.com

Anand Sweets

Bhagirath Heavy Transmission

174

CNP Pumps India Pvt Ltd

T: +91-80-25588992

T: +91-11-32222661

T: +91-22-25818400

E: info@anandsweets.net

E: bht_india1998@yahoo.co.in

E: sales@nanfangpumps.com

150

Bombay Tools Supplying Agency

T: +91-2764-291085

T: +91-22-2342 6495

E: pateldineshn@gmail.com

E: info@bombaytools.com

W: www.industrialcoatingsindia.com

W: www.bombaytools.com

Applied Technosystems

161

W: www.nanfangpumps.com

W: www.anandsweets.net Apex Industries

171

207

British Electricals

149

Coatec India

20 T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

151

Cole-Parmer India

133

T: +91-09911244140

T: +91-22-40620000

T: +91-22-67162222

E: appliedtechno@gmail.com

E: sales@britishelectricals.com

E: response@coleparmer.in

W: www.appliedtechnosystems.com

W: www.britishelectricals.com

W: www.coleparmer.in

Our consistent advertisers

208

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Pg No

Confederation Of Indian Industry

144

Advertisers’ Name & Contact Details

Pg No

Electronic Automation Pvt Ltd

Advertisers’ Name & Contact Details

G W Precision Tools India Pvt Ltd

T: +91-124-4014060-65

T: +91-80-42802345

T: +91-80-40431252

E: rachna.jindal@cii.in

E: sales@eaplindiamail.com

E: info@gwindia.in

W: www.eaplindia.com

W: www.gwindia.in

W: www.bsxindia.com

Engineering Expo Control Engg Co

137; 187

T: +91-09819552270 E: engexpo@infomedia18.in

E: ceco@cecoelectronics.in

W: www.engg-expo.com

Everest Blowers

E: sales@geapl.co.in W: www.geapl.co.in 119

T: +91-11-45457777 Controlwell India Pvt Ltd

T: +91-22-66720200

T: +91-33-22480192

W: www.cecoelectronics.co.in

Gandhi Automations Pvt Ltd

Pg No

Gelco Electronics Pvt Ltd

T: +91-79-22200902

8 E: info@everestblowers.com

E: info@gelco-world.com

T: +91-251-2870636

W: www.everestblowers.com W: www.gelco-world.com

E: connect@connectwell.com Fenner India Ltd

W: www.connectwell.com

T: +91-44-24312450 Crane-Bel Hydraulics

Festo Controls Ltd

W: www.crane-bel.com Dhakar Engineers

174

T: +91-294-2491960

161

T: +91-79-25893704

W: www.camworks.com 77

Grundfos Pumps India Pvt Ltd

T: +91-80-22894100

T: +91-44-24966800

E: info_in@festo.com

E: salesindia@grundfos.com

W: www.festo.com

W: www.grundfos.in

Flir Systems India Pvt Ltd

E: dhakareng@hotmail.com

Dr. Dinesh & Ramesh Engr. Pvt Ltd

E: inquires@camworks.com

W: www.fennerindia.com

E: office@crane-bel.com

Heattrans Equipments Pvt.Ltd.

T: +91-11-4560 3555

T: +91-79-25840105

E: manpreet.kaur@flir.com.hk

E: info@heattrans.com

W: www.flir.com

W: www.heattrans.com

Fluid Energy Controls Inc

148

Hensel Electric India Pvt. Ltd.

E: hpatel@drecasting.com

T: +91-44-42083536

T: +91-44-24541669

W: www.drecasting.com

E: sales@fecindia.com

E: henselelectric@vsnl.com

Durga Bearing Pvt Ltd

W: www.fecindia.com

109

E: inquiry@durgabearings.com W: www.durgabearings.com Elecon Engineering Company Limited

166

E: infogear@elecon.com W: www.elecon.com

Hi-Fab Engineers Pvt Ltd

T: +91-44-42152387

T: +91-22-40766555

E: info@freezetechequip.com

E: info@hi-fab.com

W: www.freezetechequip.com

W: www.hi-fab.com

22 G L Brothers

T: +91-2692-236469

.BC

160

W: www.hensel-electric.de

Freeze Tech Equipments Pvt Ltd

T: +91-22-6876073

160

T: +91-22-67056880

E: ptd.mhq@fennermail.com

T: +91-120-3263281

Geometric Ltd

169

Hindustan Motor Mfg Co

T: +91-22-66047000

T: +91-22-42500500

E: info@pilotindia.com

E: sales@hindmotors.com

W: www.pilotindia.com

W: www.hindmotors.com

120

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209

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Hi-Tech Applicator

Pg No

177

Advertisers’ Name & Contact Details

Pg No

Jyoti CNC Automation Pvt. Ltd.

.BIC

Advertisers’ Name & Contact Details

Pg No

Litel Infrared Systems Pvt Ltd

117

T: +91-79-25833040

T: +91-2827-287081

T: +91-20-66300639

E: hitech@ptfeindia.com

E: info@jyoti.co.in

E: nmshah@litelir.com,exim@litelir.com

W: www.ptfeindia.com

W: www.jyoti.co.in

W: www.litelir.com

Holani Bearings Pvt Ltd

139

Kanefusa India Pvt Ltd

T: +91-2827-293342

T: +91-124-4208440

E: vishal@holani,in

E: info@kanefusa.co.in

W: www.holani.in

W: www.kanefusa.net

Igus India Pvt Ltd

Karcher Cleaning Systems Pvt Ltd

T: +91-80-39127800

T: +91-120-4661800

E: info@igus.in

E: info@karcher.in

W: www.igus.in

W: www.karcher.in

IMI Impex Pvt Ltd

203

Kiran Manufactures

T: +91-2764-233983

T: +91-281-2388372

E: imi@imitoolsindia.com

E: info@nagmanilathes.com

W: www.imitoolsindia.com

W: www.nagmanilathes.com

Indian Machine Tool Mfgr’S Associat

156

Klipco Pvt Ltd

T: +91-80-66246600

T: +91-22-28684221

E: augustin@imtma.in

E: klipco@mtnl.net.in

W: www.imtma.in

W: www.klipcoclips.com

Inter Ads - Brooks Exhibitions Pvt Ltd

155

Knowell International Pvt Ltd

107

Macro Tech Equipment Pvt Ltd T: +91-33-24666261 E: info@macrotechcal.com W: www.macrotechcal.com

201

Makson Machines Pvt Ltd

E: makwana_eng@yahoo.com W: www.makwanaeng.com 162

Meiban Engineering Technologies Pvt Ltd 111 T: +91-80-26491229 E: sales-turning@meibanengg.com

173

MGM-Varvel Power Transmission (P) Ltd

E: ravik@mgmvarvelindia.com W: www.mgmvarvelindia.com 175

Mifa Systems

176 T: +91-79-26870825

E: sunil-chhibber@interadsindia.com

E: hktrading@vsnl.com

E: sales@mifasystems.com

W: www.knowell.co.in

W: www.mifasystems.com

28-35

Kusam Electrical Industries Ltd

T: +91-44-26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in Jaykrishna Magnetics Pvt Ltd

147

157

Mipalloy

FIC

T: +91-22-24156638

T: +91-44-24541068

E: kusum_meco@vsnl.net

E: mipalloy@md3.vsnl.net.in

W: www.kusumelectrical.com

W: www.mipalloy.com

Leuze Electronics

T: +91-44-64627008

T: +91-33-22304627

Jaibalaji Control Gears Pvt. Ltd.,

173

T: +91-278-2446437

T: +91-09810042500

W: www.india.aquatechtrade.com

121

MMI India Pvt Ltd

T: +91-79-22970452

T: +91-80-40854444

T: +91-22-42554700

E: info@jkmagnetics.com

E: manish.sahay@leuze.in

E: bhupinder.singh@mmi-india.in

W: www.magneticequipments.com

W: www.leuze.in

W: www.electronica-india.com

Jyoti Ceramic Industries Pvt Ltd

Libratherm Instruments Pvt. Ltd.

145

N S W India Ltd

T: +91-253-2350120/338

T: +91-22-42555353

T: +91-124-2372859

E: info@jyoticeramic.com

E: libratherm@libratherm.com

E: corporate@snwindia.com

W: www.jyoticeramic.com

W: www.libratherm.com

W: www.nswindia.com

Our consistent advertisers

210

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Pg No

NBM Industries

164

Advertisers’ Name & Contact Details

Pg No

Patels Airflow Ltd

183

Advertisers’ Name & Contact Details

Roto Linear Systems

149

T: +91-281-3017696

T: +91-79-40200800

T: +91-80-23572855

E: info@nbmindustries.com

E: info@steeltubeindia.com

E: rotolinearindia@vsnl.net

W: www.nbmindustries.com

W: www.steeltubeinida.com

Network 18 Publishing Pvt Ltd

152

Precihole Machine Tools Pvt Ltd

W: www.network18online.com

T: +886-3-329-9968

Rajamane Industries Pvt Ltd

T: +91-09810509716

T: +91-80-43659000

E: newautotech@rediffmail.com

E: coolantpump@rajamane.com

W: www.newautotech.in

W: www.rajamane.com

NI Systems India Pvt Ltd

12-13

Ravi Electronics

W: www.rotomotive.com 143

W: www.rupamimpex.org 143

E: ni.india@ni.com

E: sales@fluconautomationinc.com

W: www.ni.com

W: www.fluconautomationinc.com Red Lion Controls Inc.

T: +91-250-2480916 E: ncvasai@gmail.com

172

E: nmtg@nmtgindia.com W: www.nmtgindia.com Novoflex Mktg Pvt Ltd

180

E: novoflex@vsnl.net W: www.novoflexgroup.com Oil Seals Mfg Co Pvt Ltd

Sanyo Denki Singapore Pte Ltd

E: richard.chen@redlion.net

E: info@sanyodenki.in

W: www.redlion.net

W: www.sanyodenki.com 48

Sarabsukh Enterprises

101

179

T: +91-20-27292840

T: +91-1871-223893

E: info@renuelectronics.com

E: sarabsukhbatala@yahoo.co.in

W: www.renuelectronics.com

W: www.sarabsukhmachines.com 155

See Lube Technologies (P) Ltd

T: +91-22-40917777

E: infn@seelube.com

E: rexello@gmail.com

W: vww.oilandlubncant.com

181

W: www.rexello.com 164

Rightvision (India) Pvt. Ltd.

T: +91-22-22047943 E: omcoseal@rediffmail.com

Parth Poly Valves Pvt. Ltd

W: www.salvangninigroup.com

T: +91-44-42038472

Rexello Castors Pvt Ltd

T: +91-33-22260733

103

E: riddhish.jalnapurkar@salvagninigroup.com

T: +86-21-6113-3688

Renu Electronics Pvt Ltd

T: +91-79-22821527

Sal Vagnini Machinery India Pvt Ltd T: +91-80-32214123

W: www.tscindia.com NMTG Mechtrans Techniques Pvt Ltd.

113

E: rupamproducts@yahoo.com

T: +91-79-65722609

162

Rupam Products T: +91-288-2566749

T: +91-80-41190000

Nia Controls

E: info@rotomotive.com

W: www.peei.com.tw 153

Rotomotive Powerdrives India Ltd. T: +91-2692-230173

E: pshtech@gmail.com

New Autotech Industries

Pg No

178

E: sales@parthvalves.com W: www.parthvalves.com

Senor Metals Pvt Ltd

185

T: +91-120-4261026

T: +91-288-2730251

E: lasco@rightvision.biz

E: info@senormetals.in

W: www.rightvision.biz

W: www.senormetals.in

Robin Precision Products Pvt Ltd.

T: +91-79-22200198

128

181

Shachi Engg Pvt Ltd

T: +91-2827-287631

T: +91-20-66546900

E: info@bloodtools.com

E: shachi_engineering@vsnl.com

W: www.bloodtools.com

W: www.shachiengg.com

Our consistent advertisers

212

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Pg No

Shende Sales Corporation

172

Advertisers’ Name & Contact Details

Pg No

Suraj Limited

163

Advertisers’ Name & Contact Details

Pg No

Tox Pressotehnik India Pvt Ltd

141

T: +91-20-24488005

T: +91-79-27540720

T: +91-20-66538300

E: shende@shendesales.com

E: suraj@surajgroup.com

E: rnamboodiri@tox-in.com

W: www.shendesales.com

W: www.surajgroup.com

W: www.tox-de.com

Siddhapura Industries

199

Sushma Industries

T: +91-278-2445048 E: mitul@siddhapura.co.in W: www.siddhapura.co.in Sintex Industries Ltd

Tussor Machine Tools Ind P Ltd

T: +91-80-28397463

T: +91-422-3200183

E: marketing@sushmaindustries.com

E: info@tussorindia.com

W: www.sushmaindustries.com

W: www.pinachoindia.com

184 Swam Pneumatics Pvt Ltd

T: +91-2764-253500 E: icontainers@sintex.co.in W: www.sintex-plastics.com SKF Group

211

Udeyraj Electricals Pvt Ltd

T: +91-120-4696222

T: +91-22-66916181

E: swamatic@airtelmail.com

E: udeyraj@udeyraj.com

W: www.swamatics.com

W: www.udeyraj.com

157

41 SYP Engineering Co Pvt Ltd

142

Vacunair Engineering Co Pvt Ltd

169

W: www.skf.com

Sonal Magnetics

T: +91-22-28489969

T: +91-79-22910771

E: syppumps@gmail.com

E: info@vacunair.com

W: www.sypco.co.in

W: www.vacunair.com

184 Techno Industries

146

Vadodara Chamber Of Commerce & Indu

168

T: +91-79-22872349 E: info@sonalmagnetics.com W: www.sonalmagnetics.com Spareage Seals Ltd

E: sales@spareage.com W: www.spareage.com 16

E: sudhir@spco.in W: www.spco.in 51;99;145;179

E: info@technoind.com

E: info@vcciexpo.org

W: www.technoind.com

W: www.vcciexpo.org 21

Venus Engineers

165

T: +91-22-26592392

T: +91-11-32222661

E: teknic@vsnl.com

E: enquiry@venusengineers.com

W: www.tecknic.co.in

W: www.venusengineers.com

The Indian Electric Co

T: +91-22-28836879

Sumitron Exports Pvt Ltd.

T: +91-265-2642291

Teknic

T: +91-22-25800972

Spares & Components Co

T: +91-79-25830742

55; FGF

Weldor Engineering Pvt Ltd

T: +91-20-66865200

T: +91-281-2360242

E: iecmktg@indianelectric.com

E: weldor@weldor.com

W: www.indianelectric.com

W: www.weldor.com

Theeta Electricals Pvt Ltd

178

159; 185

Western Material Trading (Shanghai) Co., Ltd. 183

T: +91-11-41410631

T: +91-124-4387400

T: +86-21-5876-1508

E: sumitron@vsnl.com

E: sales@theeta.com

E: tao.cheng@wmt-china.cn

W: www.sumitron.com

W: www.theeta.com

W: www.wmt-china.cn

Our consistent advertisers

214

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Vol 15 No 11

RNI No; 67827/98 Postal Regd. No: G2 / NMD 81 2011-13 Posted at Mumbai Patrika Channel Sorting Office - GPO - Mumbai 400 001 on 22nd & 23rd of Every Previous Month Date Of Publication: 18th of Every month

November 2012 216