Search - September 2010 by Infomedia18

EDITORIAL

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EDITORIAL Executive Editor Archana Tiwari-Nayudu Features Editor Prerna Sharma Senior Features Writer Sumedha Mahorey Senior Correspondent Shivani Mody (Bengaluru) Features Writer Sandeep Pai, Sudhir Muddana, Purna Parmar, KTP Radhika Jinoy (Delhi) Correspondent Geetha Jayaraman (Delhi) Copy Desk Marcilin Madathil, Swati Sharma, Priyadarshini Basu Products Desk Michael Anthony

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SEAL OF

EXCELLENCE t’s all about being ‘tagged’. The respect and reliability that a certain country enjoys, which incidentally is also about the manufacturing might, is tough to attain and even tougher to retain. Germany as an ultimate manufacturing destination might have lost some sheen, and China, on the other hand, might be projected as the most preferred manufacturing destination lately, but there is a gaping gap in the acceptance and the perception levels in the ‘Made in Germany’ and ‘Made in China’ tag. It all about the seal of excellence!

So what about the ‘Made in India’ tag? What kind of respect and response does it evoke? And how do we move towards making the ‘Made in India’ tag a hallmark of excellence? The answers to these questions become all the more critical, as India is precociously poised for attaining excellence, but there is also a danger of restricting ourselves as a low-cost manufacturing centre, if we limit ourselves on innovation and technical know-how. According to a recent study on manufacturing competitiveness globally, India is among the top three global manufacturing hubs. Reason enough to rejoice! This report incidentally also talks about how the competitive manufacturing landscape is set to witness significant changes in the future. According to this study, the Asian manufacturing giants – China, India and Korea – will lead the sector, with the superpowers of the late 20th century – the US, Japan and Germany – lagging behind. With the Western and Asian nations vying for manufacturing dominance, the rules of the game seem to be changing. And beyond research and studies, the signs are everywhere to see that the global competitive landscape for manufacturing is undergoing a transformational shift that will reshape the drivers of economic growth, wealth creation, national prosperity and security. In this scenario, manufacturing is and will continue to be an essential path for attracting investments, spurring innovation, and creating high-value jobs. Developed and emerging nations are in heated competition to create the most compelling opportunities to innovate, build a highly-skilled workforce and improve the standards of living. That again brings us back to India…where are we positioned? The importance of India to manufacturing executives around the world underscores two important points. First, strength in R&D – paired with engineering, software, and technology integration abilities – are viewed by global executives as vital elements of the talent-driven and innovative manufacturing enterprise of the 21st century. Second, manufacturing executives increasingly view India as a place where they can design, develop and manufacture innovative products for sale in local as well as global markets. This Special September issue of SEARCH is dedicated to ManuFuture and the rise of the new world order. Here’s presenting you a whole new world of opportunities. The content spread is so designed and conceptualised so as to help every manufacturer grow and gain. The aim is also to enable each Indian in ascertaining that India’s growth story is a sustainable one. Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

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

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CONTENTS EXTREME ENGINEERING

ROSUB 6000

| Pg 92

Touching The Heart Of Ocean With the increasing demand for expertise to perform multiple deep sea operations for mining and oil & gas industry, the successful development of ROSUB 6000, a Remotely Operated Vehicle, has lifted India’s potential and credibility on the global map in research competency. This deep sea technology, developed by National Institute of Ocean Technology, Chennai, is a first of its kind in India and has opened up sea of opportunities to explore the vestal offshore full of extremities.

SPECIAL REPORT Image courtesy: NIOT

EDITORIAL

Global Manufacturing Competitiveness Correlating Diverse Factors To Attain Excellence

102

Rise Of The New World Order

110

Remanufacturing A Hidden Green Giant Ready To Take The Leap

Seal Of Excellence

VIEW FROM THE TOP

NATIONAL NEWS Latest In The Indian Manufacturing

Pg 88 NEWS ANALYSIS 44

Solar Power Projects Selection Criteria Guiding The Solar Mission

WORLD NEWS Snapshot Of Latest Global Happenings In Manufacturing Domain

TECHNOLOGY TRENDS 116

Technology Update Cutting Edge Solutions

APPLICATION ZONE 120

Human Machine Interface Where Sophistication Meets Simplicity

EQUIPMENT BUYING GUIDE 124

SLIP Ring 6 Easy Specifications To Ensure A Perfect Fit

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‘The Thrust On R&D Will Fuel The Growth Of Instrumentation & Control Equipment’ JOHN O’HIGGINS, Chief Executive, Spectris Plc

CONTENTS SPECIALS IN THIS ISSUE INDUSTRY UPDATE Instrumentation & Control

Instrumentation & Control Advancing Towards Smarter Solutions

Next-Gen Technologies Instrumental For ‘Intelligent’ Manufacturing

INSIGHTS & OUTLOOK Pumps & Valves

Automation Trends In Instrumentation & Control Moving To A Wireless Infrastructure IT In Control Systems Securing Information & Operational Networks

Pumps & Valves Gushing Ahead With Force

Machine Safeguarding Enhancing Equipment & Worker Safety

DESIGN INNOVATIONS

Case Study

Seepex Pumps In Fodder Processing Transporting The Right Dosage At Stable Pressure

PRODUCT UPDATE

128

Design & Business Why Can’t We Be Friends?

150

Instrumentation & Control Latest Products In The Instrumentation & Control

132

Innovators’ Outlook ‘The Power Of Industrial Design Is Realised Not By An Amazing Idea, But By The Ability To Deliver It’ JASHISH KAMBLI, Executive Partner – Design & Development, Future Factory

162

Pumps Latest Products In The Pumps

166

Valves Latest Products In The Valves

172

New Launches Latest Products In The Offing

174

General Products Rolling Out The Best-in-class

218

International Products Showcasing Product In A Global Arena

SMART STRATEGIES 134

Plastic To Fuel ‘FUEL’ For Thought

SME ADVANTAGE 138

Lean Practices Augmenting Performance, Maximising Value

211

CURTAIN RAISER 142

Electronica India + Productronica India 2010 All Set To Energise The Electronics Industry

PRODUCT INQUIRY FORM For Product Inquiries Showcased In This Issue, Fill In The Form And Send It Back To Us

226

PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

REPORT 144

Leadership Through Industrial Design Inspiring Design Success Through Collaboration

146

ARC 8th India Forum Leveraging Automation To Drive Business Excellence

148

AMTEX 2010 Tapping Global Opportunities

PRODUCT UPDATE

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233

ADVERTISEMENT INQUIRY FORM Get In Touch With Supplier Of Products You Wish To Buy

238

ADVERTISERS’ LIST Advertisers’ List In Chronological Order

NATIONAL NEWS

Duty exempted on imported goods for mega power projects he conditions for projects based on the superlocated in Jammu & Kashmir grant of excise critical coal-thermal technology, and the Northeastern states. duty exemption for with an installed capacity of Moreover, the chief goods supplied to 3,960 MW or above, from engineer of the Central mega power projects have which power procurement has Electricity Authority has been been amended. Thus, project been tied up through tariffgiven the power to attest the developers, instead of the based competitive bidding. list of goods required for setting manufacturers, will now pay The prescribed documentation up the projects. Dated March 1, 2006, excise the duty if they do not ensure includes an undertaking from the use of exempted the Chief Executive Project developers, instead of the Officer of the project goods in their projects. Thermal power manufacturers, will now pay the duty if that the exempted projects that can will be used they do not ensure the use of exempted goods generate 1,000 MW only in the said project goods in their projects. power and hydel and not for any other power projects that use. In the event of exemption notification number can generate 500 MW power failure to do so, the project 6/2006-CE has three different are referred to as mega power developer will pay the duty. S.No. 91 B of the notification dispensations for power projects. Goods required for exempts goods supplied to projects. S.No. 91 exempts all such mega power projects can mega power projects from goods supplied against be imported duty-free. Locally which supply of power has International Competitive produced goods, which are been tied up through tariffBidding, if such goods can be supplied to such projects, can based competitive bidding or a imported at zero duty. be cleared without excise duty S.No. 91A of the notification mega power project awarded payment. The threshold limits exempts goods required for to a developer on the basis of are 700 and 350 MW, setting up ultra mega power such bidding. respectively, for projects

FDI Equity Inflows (Month-wise) During The Financial Year 2010-11: Financial Year 2010-11 (April-March ) April 2010 May 2010 2010-11 (Up to May 2010) # 2009-10 (for May 2009) %age growth over last year

Amount of FDI inflows* (In Rs. Crore) (In US$ mn) 9,854 2,214 10,135 2,213 19,989 4,427 21,876 4,434 ( - ) 9.0 % ( - ) 0.2 %

Sectors Attracting Highest FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)

Sector Services Sector Computer Software & Hardware Telecommunications Housing & Real Estate Construction Activities Power Automobile Industry Metallurgical Industries Petroleum & Natural Gas Chemicals

2010-11 % age to total (April -May Inflows 2010) (In terms of US$) 2,643 21% 1,333 9% 4,023 9% 738 7% 594 7% 1,416 4% 222 4% 2,101 3% 757 2% 175 2%

Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to May 2010) - Annex-â&#x20AC;&#x2DC;Bâ&#x20AC;&#x2122;.

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NATIONAL NEWS

Steel makers look towards costeffective technology he steel manufacturing industry is looking forward to a revolution with major players concentrating on upgradation and modernisation of facilities. The focus is on utilising iron ore fines to produce steel. The front-runner, Steel Authority of India (SAIL), is in discussions with two foreign steel majors for using this technology. Similarly, private players are also gearing up, as Jindal Steel and Power (JSPL) recently acquired Shadeed Iron and Steel Company’s new plant in Oman, which has adapted this technology. The company aims to reduce its production cost by 15-20 per cent by using hot briquetted iron. “India has abundant iron ore fines; however, these need to be

sterilised and processed using FINEX technology before being put into use. Unfortunately, India did not have this technology earlier, so we had to export these iron fines. However, now, JSPL is the first to bring this technology to the country, and hence, we are reducing the overall production cost of steel,” says Sushil Maru, Director-Finance, JSPL. SAIL is also in talks with Kobe Steel for setting up a plant near Durgapur, where Kobe will provide its patented ITMK3 technology that uses iron ore in the form of nuggets. Also, SAIL plans to use coke dry quenching facilities, in coke ovens in the five blast furnaces that it is upgrading. This would help the company increase coke production and reduce its coking coal demands.

Control panels & switchgears on an upswing t its AGM held recently, the Control Panel and Switchgear Manufacturers Association (COSMA) has predicted a steady growth in the near future. Highlighting the same, PK Ranade, JMD, Indo Asian Fuse Gear, avers, “There are 1 million strong middle class households in India, translating into increase in demand for quality control panels and switchgears. The robust 2025 per cent growth rate is going to stay.” Addressing the members, Soeb Fatehi, President, COSMA asserted, “Technology is going through a rapid change. Together, we can serve the cause of the industry, its growth and distribution.”

Share Of Top Investing Countries FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)

Country Mauritius Singapore U.S.A. U.K. Netherlands Japan Cyprus Germany France U.A.E. Total FDI Inflows *

2010-11 % age to total Inflows (April-may 10) (in terms of US $) 5,854 42% 3,856 10% 802 7% 507 5% 1,358 4% 1,647 4% 237 4% 136 2% 284 1% 46 1% 19,989 -

Note: (i) *Includes inflows under NRI Schemes of RBI, stock swapped and advances pending for issue of shares. (ii) Cumulative country-wise FDI equity inflows (from April 2000 to May 2010) – Annex-‘A’. (iii) %age worked out in US$ terms & FDI inflows received through FIPB/SIA+ RBI’s Automatic Route+ acquisition of existing shares only. Source: Department of Industrial Policy & Promotion, Ministry of Commerce and Industry, Govt. of India

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NATIONAL NEWS

EVENTS

PUNE Maharashtra November 19-22, 2010 Auto Cluster Exhibition Ctr, Chinchwad

AHMEDABAD Gujarat December 10-13, 2010 Gujarat University Exhibition Hall

INDORE Madhya Pradesh January 7-10, 2011 Maharaja Shivajirao School Grd, Chimanbaug

CHENNAI Tamil Nadu March 11-13, 2011 Chennai Trade Centre

India’s premier industrial trade fair on products and technologies from machine tools, hydraulics & pneumatics, process machinery & eqpt, automation instrumentation, packaging & auxiliaries, IT products, electrical & electronics, material handling, safety eqpt.

Concurrent Shows

MUMBAI Maharashtra February 17-19, 2011 Bombay Exhibition Center

One of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, it products, electrical & electronics with a special focus on automation & instrumentation, material handling For further details contact: Tel: 022 3003 4649/4651 Fax: 022 30034499 Email: engexpo@infomedia18.in Web: www.engg-expo.com INTEC 2010 Focus: Industrial Goods When: September 1-5, 2010 Where: Codissia Trade Fair Complex, Coimbatore Tel: +91-422-2221582 Fax: +91-422-2222131

Any policy rate hike by RBI to impact SMEs: Survey

In India

ny hike in shortcurb the inflation.” impact of the RBIs move. The survey was based on Since February this year, term borrowing the responses from 200 small the RBI has been tightening its and lending rates entrepreneurs. The high cost monetary policy to control by the RBI will go at which credit is made inflation. In its monetary review against the interest of small and available to SMEs is the last month, it raised the shortmedium enterprises (SMEs). foremost impediment to term lending and borrowing This is because it will increase rates by 25 basis points their production costs and hamper their The RBI should desist from increasing each. In order to help the competitive advantage, sector, the says the PHD Chamber interest rates in the quest of curbing SME further of Commerce and inflation, as this would raise production chamber Industry (PHDCCI) costs and hamper the competitive suggested that the lending mechanism of survey. advantage of SMEs. banks should be furhter There are about 2.6 streamlined. “Delays in crore micro, small and enhancing their growth and sanction, renewal, disbursement medium enterprises, which competitiveness in domestic of loans and documentation contribute about 45 per cent and global markets. Reacting procedures should be avoided,” to the country’s manufacturing to this survey, the RBI officials it said. Amid spiralling inflation, output and 40 per cent to said, “This is bound to happen the RBI has planned to review exports. but we cannot help it as it is the monetary policy again in Thus, a majority of these only way by which we can September. players are now feeling the

Siemens develops largest single-phase transformer iemens recently manufactured India’s first and largest single-phase 500 MVA HVDC transformer at its Kalwa factory. This adds to its indigenous manufacturing capabilities to meet the Indian power sector requirement for making high-technology products. The transformer will be used in the HVDC Transmission system to

efficiently transmit bulk power over long distances. The converter transformer with a single-phase rating of 500 MVA will be connected to form a bank of 1,500 MVA, operating at a voltage of 500 kV. This is the largest rating transformer ever, as other local manufacturers have produced a rating of only one-third till now. Siemens plans to use these

transformers for the Adani Power project where it is currently constructing a bipolar 2,500 MW HVDC system, which will be commissioned early next year. Systems using this transformer will have the capacity to transmit bulk power of 2,500 MW over 900 km from a power plant near Mundra to the industrial regions of Haryana.

IPTEX 2010–Trends in gear engineering technology n manufacturing world, improved process efficiency greatly depends on superior power transmission mechanisms. These mechanisms, if efficient, help in optimising productivity at a lowest possible cost. To update the industry on the available power transmission equipment and machinery manufacturers,

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the International Power Transmission Expo (IPTEX 2010), an exclusive exhibition focussing on gear engineering technology, was held at Bombay Exhibition Center, Mumbai, on May 20-22, 2010. The event was supported by American Gear manufacturers’ Association. The event saw participation from countries like the US,

Finland, Switzerland, Germany, Italy, Czech Republic, Japan and India, with over 2,500 visitors from several countries. It covered the latest trends and technology prevalent in the power transmission industry. Products on display included gears and gear boxes, metrology products, software, bearing, other mechanical transmission products, etc.

NATIONAL NEWS

EVENTS

In India

ELECTRONICA & PRODUCTRONICA INDIA 2010 Focus: Electronic Products When: September 7-10, 2010 Where: Bangalore International Exhibition Centre (BIEC), Bangalore Tel: +(91)-(22)-26452101 Fax: +(91)-(22)-6516372 PROMACH 2010 Focus: Tools and Tooling Equipment When: October 1-4, 2010 Where: Bangalore International Exhibition Centre, Bangalore Tel: 080-80-65833234 Email: dayanand@bies.co.in INDIA ENERGY 2010 Focus: Technologies in renewable energy When: October 7-9, 2010 Where: Bombay Exhibition Centre, Mumbai Tel + 91 22 6612 2644 Fax: + 91 22 6612 2626-27 Email: abhijit.mukherjee@ubm.com Website: http://www.ubmindia.com IPVS - INDUSTRIAL PUMPS, VALVES AND SYSTEMS Focus: Industrial pumps, valves and systems When: December 9-11, 2010 Where: Chennai Trade Centre, Hall 3, Tamil Nadu Tel: + 044 - 22316033, 044 - 22315551 Fax: + 91 22 24102805 Email: info@ipvs.in / ho.exb1@ orbitzexhibitions.com HANNOVER MILANO FAIRS INDIA Focus: Concurrent trade shows on material handling & logistics; motion, drives & automation; building automation; energy & surface technology When: December 15-18, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: +91 22 40050681/82 Fax: +91 22 40050683 Email: info@hmf-india.com EA WATER EXPO Focus: Water and Wastewater Management When: January 06-08, 2011 Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-29531288 Fax: +(91)-(11)-29531291

Industrial output slows as year-ago base effect fades ndia’s factory output slowed in June after 8 months of doubledigit growth, as demand cooled and the base effect of a year ago faded away. Commenting on the same, Montek Singh Ahluwalia, Deputy Chairman, Planning Commission says, “Despite the slowdown, the economy will maintain its 8.5 per cent growth rate.” The Index of Industrial Production (IIP) declined to a 12-month low of 7.1 per cent. It was 8.3 per cent in the same month last year, and 11.3 per cent in May, while China’s IIP slacked to an 11-month low of 13.4 per cent in July. Analysts believe the reasons for the

output slowing down in the 2 fastest growing economies are different. Samiran Chakraborty, Chief Economist, Standard Chartered Bank, says, “The slowdown in China was policy-induced, while in India, it was due to the internal dynamics of the demand cycle. The high industrial output growth in India was due to the unusually high spate of demand and inventory restocking. That is coming to an end. The slowdown is further guided by the fading away of the base effect. In that sense, it is not slowdown but coming back to the normal growth trajectory.” Taimur Baig and Kaushik Das, Economists, Deutsche Bank

AG, assert, “The slowing of industrial production growth is likely to hit headlines, but, in fact, production remains strong. On a seasonally adjusted basis, industrial production rose by 1.1 per cent month-onmonth.” But Mridul Saggar, Chief Economist, Kotak Securities, says that the slowdown in IIP growth is partly policy-induced. “Withdrawal of fiscal stimulus has impacted aggregate demand as government consumption demand has slowed down.” With rising interest rates and increasing capacity constraints in the economy, analysts expect IIP to continue to grow in single digits in the coming months.

Rittal’s automation packaging solutions at IGI Airport ith the increasing competition in the aviation sector, where companies are competing for airport infrastructure, Rittal has managed to stay ahead. Having already made a mark in over 60 world-class airports worldwide, eg, Frankfurt, Singapore, Munich, etc, the firm has also provided airport solutions at Bengaluru International Airport (BIAL), Hyderabad International Airport, Shamshadbad, Mumbai International Airport. Rittal’s new product offerings at Indira Gandhi International (IGI) Airport Terminal 3 include

Rittal Enclosures for baggage handling

enclosures, cooling units, power distribution systems, networking & server racks to kiosk systems. Terminal 3 at the airport is connected to the New Delhi city centre by a dedicated high-speed Metro line. Eight trains are deployed in this line, with each train containing 6

coaches and operating at 10 minute intervals. Besides baggage handling systems, Rittal has supplied over 100 stainless steel enclosures for baggage handling system on trains. These are special EMC & EMI compliant enclosures that have been tested after integration at an independent laboratory (Wipro in Bengaluru). These enclosures are subjected to electromagnetic field, radiation emission, surges and electrostatic discharge. The test has been successful, meeting all critical requirements for on-board applications.

Amtech Electronics installs largest direct MVD in Asia mtech Electronics (India) recently installed a 7.7 MW/11 KV Medium Voltage AC Variable Frequency Drive (MVD) at Hindalco Industries. Amtech Electronics (India) is a flagship company of

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the Amtech Group of Companies, based at Gandhinagar, and is in the business of motion control and automation. Hindalco is also a flagship company of the Aditya Birla group. With this installation, Piyush Patel,

Director, Amtech Electronics (India), said, “We expect to reduce the electric power consumption by 15-20 per cent in SO2 blower application.” This is the largest direct MVD installation of its type in Asia, according to Patel.

SOLAR POWER PROJECTS SELECTION CRITERIA

GUIDING THE

S LAR MISSION With the Ministry of Power and Ministry of New & Renewable Energy releasing the guidelines for selection of New Grid Connected Solar Power Projects under the Jawaharlal Nehru National Solar Mission, India has moved one more step ahead in becoming a recognised solar power producing nation. However, some critical sections in the guidelines need more clarity before the actual implementation takes place. It is also equally important that the implementation of the guidelines takes place unhindered for achieving all the said objectives. SANDEEP PAI n June 25, 2010, Dr Farooq Abdullah, Hon’ble Union Minister for New and Renewable Energy, and Sushil Kumar Shinde, Hon’ble Union Minister for Power, jointly unveiled the guidelines for selection of new solar power projects under the 1,000 MW solar power scheme in the first phase of the Jawaharlal Nehru National Solar Mission ( JNNSM). After releasing the guidelines, the ministers jointly stated, “We would be able to generate 500 MW of solar-thermal power and another 500 MW from photovoltaic cells in the next three years.” This is significant as it would place India in the league of nations such as Germany, Spain and Japan, which are considered as leaders in harnessing solar power. According to the guidelines issued, the project is planned to be implemented with

the financial assistance from Power Finance Corp (PFC) and Rural Electrification Corp (REC). “PFC and REC would finance some of the projects,” Shinde said, adding that Indian Renewable Energy Development Agency (IREDA) will also fund these projects. Furthermore, the nodal agency for sale and purchase of power under the solar mission will be NTPC Vidyut Vyapar Nigam (NVVN). They will be responsible for inviting expressions of interest from developers for solar photovoltaic projects under this scheme. In order to have wider participation from solar power developers, only one application per company – including its parent, affiliate or group company – shall be permitted for the development of a single project. Moreover, the projects should be of 5 MW or more in case they use solar photovoltaic cells in order to connect to the transmission

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company’s substations. While the mission was launched a long time back, the guidelines will determine how it will be implemented and its future course. Moreover, these guidelines will affect every player in this sector. The guidelines in general have been welcomed by the experts in the industry, but there are some aspects that need to be addressed for their effective implementation.

A WELCOME MOVE The India Semiconductor Association (ISA) welcomes this development and is confident that these policy measures would give impetus to the growth of the domestic solar PV industry. The association believes that it is a concrete step in realising the targets set by the National Solar Mission and will provide a significant boost to the domestic solar industry. Elucidating further, Deepak Puri, CMD,

SOLAR POWER PROJECTS SELECTION CRITERIA

Moser Baer India, averred, “Needless to say, these guidelines are timely and topical and are bound to give a strong impetus to the solar industry, both in terms of marketing and manufacturing, to achieve the solar mission’s target.”

According to the ISA, “This would greatly benefit the domestic cell and module companies and also To facilitate a quick start-up of the JNNSM attract foreign investments into To ensure serious participation for projects to be the country in the area of solar PV selected under JNNSM manufacturing.” Puri said, “By mandating the To facilitate speedier implementation of the new ‘Made in India Content’, the projects to be selected to meet the Phase I target government has vindicated the of JNNSM CRITERIA FOR criticality of Indian solar To enhance confidence of the project developers SELECTION manufacturing sector. This will The selection criteria of new grid additionally ensure faster reduction To promote solar equipment manufacturing in connected projects through bid in costs through indigenisation. It India. process are challenging as these will definitely help the Indian solar might lead to ‘adventurous’ bids manufacturing industry in scaling by companies not conversant with the solar power purchase agreement (PPA) with up capacities and moving up the technology energy sector. However, Puri who is solar power generation project developers, curve.” optimistic about government decisions said, who will be setting up solar projects during While this particular directive will “I am confident that the government will be the next three years, i.e., before March certainly give Indian manufacturers a chance able to ensure shortlisting of only serious 2013 and are connected to the grid at a to expand and create their own developers for implementing the projects voltage level of 33 kV and above. manufacturing space, it is important that we and that the penalties for non-performance The guidelines further mention that for should encourage our manufacturers to will be serious.” However, expressing each MW of installed capacity of solar compete globally. concerns about the selection procedure power for which a PPA is signed by NVVN, Commenting on this criterion, Bhabu that will be undertaken as per the guidelines, the Ministry of Power shall allocate to says that India is encouraging the Shaleen J Bhabu, Founder, Quest Solar, NVVN an equivalent amount of MW development and use of obsolete noted, “The policy in general is good, but is capacity from the unallocated quota of technology. “We currently have unfavourable for entrepreneurs. Any startNTPC coal-based stations and NVVN will manufacturers, who supposedly compete up will have difficulty in meeting the netsupply this ‘bundled’ power to the globally with their modules. This should be worth criterion. It has been designed to distribution utilities. done for the domestic market as well, keep entrepreneurs out of this venture.” When asked about the bundling scheme, instead of resorting to ‘protectionism’ and “Instead of looking at the capability of the Puri, said, “Till the time solar sector achieves ‘license Raj’. Moreover, we need to be team to develop and deliver the parameter, grid parity (perhaps a few years away), it globally competitive,” he added. the criterion looks for financial muscle. Also, would be important for schemes such as Apart from these issues, the government the selection based on the discounts to be bundling price mechanism to continue. This should ensure that there is uninterrupted offered on the Central Electricity Regulatory will certainly help the government to bring implementation of the guidelines for making Commission (CERC) guideline, ensures down the cost to the exchequer in the mission successful. If this is done, these that people with deep pockets get the promoting solar energy generation.” guidelines will facilitate quick start-up of the contract as they will have the ability to Demanding more clarity, Bhabu says that JNNSM giving India a solar energy boost. withstand losses for a longer time,” Bhabu there are no issues with the bundling Under JNNSM, the government has set adds. scheme in theory, but I am unsure about a target of generating 20,000 MW of how it is going to work during peak usage electricity by tapping solar energy. The BUNDLING PROCESS time, and if there is no unallocated power. target would be implemented in three Apart from the selection procedure, another He further questions, “What would be the phases – phase I up to 2012-13, phase II area of concern has been the ‘Bundling perspective of the utilities who will have to from 2013-2017, and phase III from 2017Scheme’ in the guidelines. In order to buy the ‘bundled’ power?” 2022. facilitate grid connected solar power MANUFACTURING: BOON OR TOWARDS BRIGHTER FUTURE generation in the first phase, a mechanism BANE? The government has been quite serious of ‘bundling’ relatively expensive solar Furthermore, as per the guidelines, it will be with regard to policy development and power with power from the unallocated mandatory for the projects based on c-Si announcement of the guidelines. Now, it is quota of the Government of India (Ministry (crystalline silicon) technology to use the equally important that the same level of of Power) generated at National Thermal modules manufactured in India for 150 MW commitment is seen in the implementation Power Corporation (NTPC) coal-based of solar PV power projects to be selected of the policy as well. Moreover, with regard stations, which is relatively cheaper, has during the current FY 2010-11. During the to the guidelines, the government should been proposed by the mission. This FY 2011-12, over 300 MW of solar PV ensure transparency in the selection process ‘bundled power’ would be sold to the power projects would be selected where it and address issues related to the bundling distribution utilities at the CERC determined will be mandatory for all the projects to use process. If these issues are sorted out, then prices. The nodal agency (NTPC) will cells and modules manufactured in India. the sun won’t set on solar power. procure the solar power by entering into a

Guidelines objectives:

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WORLD NEWS

EVENTS

FIMAQH Focus: Tools & Tooling Equipment When: September 9-14, 2010 Where: Centro Costa Salguero, Buenos Aires, Argentina Tel: + (54)-(11)-43431493 IFAT Entsorga Focus: Water, Sewage, Refuse and Recycling When: September 13-17, 2010 Where: New Munich Trade Fair Centre, Munich, Germany Contact: Haleema Sayed India Representative - Munich Fairs, Indo German Chamber of Commerce Tel:022-66652127 Fax:022-66652120 E: munichfairs@indo-german.com IMTS 2010 Focus: International Manufacturing Technology Show When: September 13-18, 2010 Where: McCormick Place, Chicago, IL, USA Tel: 703-827-5252 Fax: 703-827-5250 Email: jkrisko@amtonline.org Web: www.imts.com Intertool Moscow Focus: Tools & Tooling Equipment When: October 5-8, 2010 Where: Crocus Expo International Exhibition Center, Moscow, Russia Tel: + (1)-(203)-8404800 Fax: + (1)-(203)-8404801 BIMU Focus: Tools & Tooling Equipment When: October 5-9, 2010 Where: Fiera Milano, Milan, Italy Fax: + (39)-(2)-26255214 MM Live Focus: Manufacturing & Repair When: October 19-20, 2010 Where: Ricoh Arena, Coventry, United Kingdom

US urged to revitalise manufacturing

Abroad

S Commerce Secretary, Gary Locke, recently issued a call for action to revitalise the nation’s manufacturing sector. “A vibrant manufacturing sector is not just critical for the millions of Americans whose jobs depend on it. Manufacturing is absolutely central to driving the innovation that fuels the American economy,” Locke said as he appointed new members to the 2010 Manufacturing Council. Among the 24 manufacturing leaders

appointed to the Council, was Michael Laszkiewicz, VP & GM - Power Control Business, Rockwell Automation. Laszkiewicz said that the Council’s work comes at a critical moment for American manufacturers. “Ten years from now, global manufacturing will look nothing like it does today. We hope that the federal government will join forces with American manufacturers to foster the next round of technological innovation that will create highly efficient smart factories.” Locke further

Manufacturing is absolutely central to driving the innovation that fuels the American economy. GARY LOCKE, US Commerce Secretary

said that the Council will bring ideas for the methods using which the federal government can support manufacturing and exports.

German GDP witnesses biggest jump in 23 years he gross domestic product (GDP) of Germany grew 2.2 per cent in the second quarter. According to the Federal Statistics Office (Destatis), it was the biggest gain in 23 years, driven by investments and exports. The first-quarter growth was revised to show a growth of 0.5 per cent, after being previously reported at 0.2 per cent. Year-on-year (YoY), the

economy grew by 4.1 per cent in the second quarter. This followed a revised 2.1 per cent expansion during JanuaryMarch and met the expectations for 2.4 per cent growth YoY. “Reunified Germany has never seen such quarterly growth before,” a Destatis statement said in reference to the second-quarter figure. The economy grew by 4.4 per cent annually in the quarter. The record figure is more notable,

with the growing concerns that the US and now China, the Asian powerhouse, are showing distinct signs of slowing, raising questions about the overall global recovery. While Germany normally relies on exports to underpin growth, it is the second biggest exporter worldwide after China. “Household and government final consumption expenditure also contributed to GDP growth,” added Destatis.

Japan’s growth slows as recovery loses steam apan’s economy has witnessed a much weaker rate of growth than expected in the second quarter this year. Japan’s real GDP grew by an annualised 0.4 per cent in the quarter, down from a revised 4.4 per cent in the previous three months and missing forecasts of 2.3 per cent growth from a Dow Jones Newswires poll of economists. On a quarterly basis, growth was at 0.1 per cent, down from a revised 1.1 per cent in the previous quarter. Commenting on the

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development, Chiwoong Lee, Economist, Goldman Sachs opines, “With the government currently focussed on fiscal reconstruction, the chances of additional fiscal spending are declining sharply.” The cooling exports and flat domestic consumption hitting Japan’s growth in April-June have pointed to the looming prospect of China overtaking Japan as the world’s secondlargest economy. Commenting on the current state of the economy, Keisuke Tsumura, Parliamentary Secretary, Cabinet Office, avers, “The

economy is levelling off.” On a nominal basis, Japan’s second quarter GDP was smaller than China’s, at $1.288 trillion as compared to $1.336 trillion. Shipments of cars, gadgets and components have been crucial in offsetting weaker demand at home, but concern is mounting that Japan may be hit by Beijing’s efforts to cool China’s economy, as well as fragile Euro zone and US demand. Also, Japan’s exporters are threatened by a slowdown overseas, cooling a sector that is anxious about the strength of the Yen.

WORLD NEWS

China’s new-energy vehicle base to produce 10,000 units yearly he largest newenergy vehicle production base of Northeast China’s Heilongjiang province opened in Qiqihar city recently. The industrial park is expected to achieve an annual production of 10,000 units of solar-energy and hybrid vehicles. With a total investment of 1.5 billion Yuan (US$220.5 million) and covering an area of

668,000 sq m, the project is set to develop in three phases. Phase 1: The production base will produce 1,500 units a year, of traditional buses or vehicles for special usage. Phase 2: One million electric vehicles along with their engines and control systems will be designed and manufactured. Phase 3: The production base will produce 100 MW

solar energy PV modules, and increase the production capacity and hybrid vehicles to 10,000 units. In 5 years, the production base is predicted to attract annual sales income of 48.6 billion Yuan along with pre-tax profit of 5.7 billion Yuan. Moreover, developments in related industrial sectors, making way for a regional R&D centre for new-energy vehicles are expected to be achieved.

BGR Energy to join hands with Hitachi Group GR Energy Systems, engaged in supplying systems and equipment and turnkey engineering project contracting, has recently signed joint venture (JV) agreements with Hitachi, Japan, and Hitachi Power Europe, Germany, a Hitachi subsidiary. The JV with Hitachi, Japan, is for design, manufacture, installation and commissioning of supercritical steam turbines

and generators for thermal power plants while the second JV with Hitachi Power Europe, Germany, would be for supercritical steam generators for thermal power plants. BGR Energy looks forward to offer complete boiler, turbine-generator solution to the Indian power industry. According to industry experts, the current per capita consumption of electricity at 750 kWh per annum is likely to

increase to 1,000 kWh per annum by 2012 and will grow to at least 3,000 kWh, as is the case with China. The installed power-generation capacity of approximately 1,50,000 MW is set to grow multifold. A leading consultant has projected a capacity of about 7,50,000 MW by 2027. Thermal power, which constitutes about 70 per cent of the total generation, will provide bulk of this additional capacity.

Timken to acquire QM Bearings & Power Transmission Inc o expand its process industry portfolio, Timken has acquired QM Bearings & Power Transmission Inc, in July 2010. QM, based in Ferndale, Washington, manufactures spherical roller bearing steel-housed units and elastomeric and steel couplings, which are used in demanding processes like sawmill and logging operations. With the acquisition of QM, Timken can easily penetrate high-performance applications and extend its power transmission capabilities beyond the company’s original, core business of bearings. Also, the acquisition

will help the company to provide customers with a wider breadth of friction management and power transmission solutions for extending the life of their machinery. The company officials said, “This acquisition gives Timken distributors immediate access to a proven line of spherical roller bearing housed units and elastomeric and steel compression couplings. They will now have access to cast steel housings, 15 sealing configurations, 4 locking collar options and a total product portfolio in excess of 29,000 part numbers.” This venture will strengthen the hold of the Timken brand

in the roller housed unit category and provide an additional offering for markets that need high-performance, durable products. Chris Coughlin, President, Timken’s Process Industries, explained, “QM is a great addition for Timken, with a solid, valueadded product line that extends our portfolio to offer a wider selection of highperformance products for our customers in the process industries.” The acquisition will add to the total earnings in its first year, subject to certain government and regulatory approvals. The transaction is expected to be closed by the fourth quarter of 2010.

EVENTS

Abroad

Tel: + (44)-(1829)-770037 Fax: + (44)-(1829)-770047 2010 Advanced Manufacturing & Technology Show Focus: Manufacturing and Machinery When: October 20-21, 2010 Where: Dayton Airport Expo Center, 2900 McCauley Dr Vandalia, OH 45377 US Tel: 937-512-3862 Fax: 937-512-3224 Tooltec Expo Focus: Tools & Tooling Equipment When: November 4-6, 2010 Where: Prague Exhibition Grounds, Prague, Czech Republic Tel: + (420)-(220)-103111 Fax: + (420)-(233)-379450 American Manufacturing Strategies Summit Focus: Manufacturing and Machinery When: November 11-12, 2010 Where: Hilton Chicago - Indian Lakes, Chicago, IL Tel: 1 416 214 1144 Fax: 1 416 214 3403 SHEET METALEX Focus: Manufacturing and Machinery When: November 24-27, 2010 Where: Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand Tel: + (66)-(2)-6867299 Fax: + (66)-(2)-6867288 Machine Tool Indonesia Focus: Tools & Tooling Equipment When: December 1-4, 2010 Where: Jakarta International Expo (JIExpo), Jakarta, Indonesia Tel: + (44)-(20)-78402100 Fax: + (44)-(20)-78402111

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INSTRUMENTATION & CONTROL

INSTRUMENTATION & CONTROL: Advancing Towards Smarter Solutions .................................56 NEXT-GEN TECHNOLOGIES: Instrumental For ‘Intelligent’ Manufacturing .................................60 AUTOMATION TRENDS IN INSTRUMENTATION & CONTROL: Moving To A Wireless Infrastructure .................................................................................................64 IT IN CONTROL SYSTEMS: Securing Information & Operational Networks .................................69

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INSTRUMENTATION & CONTROL

KTP RADHIKA JINOY echnological advancements in instrumentation and control (I&C) systems, over the past decades, have contributed immensely towards productivity enhancement in manufacturing industry. The growing need for control and computing has created a huge scope for research in instrumentation, as it plays a significant role in gathering information from

TRENDS IN I&C Convergence Process control is becoming more efficient today as a result of the ever-increasing computing power of chips, the network bandwidth offered by Ethernet, and the availability of vast data storage capacities at an economical cost. Elaborating on the benefit of convergence, Pradeep Karnik, Business VP â&#x20AC;&#x201C; Industry, Asia-Pacific Operating Division, Schneider Electric, observes, â&#x20AC;&#x153;The technological advancements in the field of control have largely led to a convergence of the erstwhile classical

the real-time information visibility right up to their motors, instruments and actuators.â&#x20AC;? This information is allowing manufacturers to take real-time decisions, facilitating them to anticipate and respond faster to events unheard of in the earlier analog era. From a vendor perspective, Ethernet also enables to create more value for manufacturers without being distracted by the network/ Fieldbus wars of earlier periods. Of course, the economic downturn and global warming have made manufacturers more pragmatic about process control technology, while being proactive about energy-efficiency. No

ADVANCING TOWARDS

SMARTER SOLUTIONS

Over the last few years, instrumentation and control systems have been continuously evolving. Advancements in wireless technology, shift from analog to digital era, developments in integration and convergence, vast data storage capacities, etc have widened the scope of their applications. These smart systems have proved to be a boon for the manufacturing industry, enabling manufacturers to boost performance, cut costs, save energy and improve efficiency in every domain. the field and also changing the field parameters. A properly planned, designed, constructed and maintained I&C system provides accurate and appropriate information and ease of operation at manufacturing facilities. They have, therefore, become vital elements for safe and efficient production processes and the emerging trends in the area of I&C are changing the face of the manufacturing industry.

programmable logic controller (PLC) and distributed control system (DCS), offering the manufacturing industry with a choice of process control options that best meet their specific needs. Moreover, intelligence has percolated into such systems right from the classical processor into the devices, be it the field instruments or actuators or the ubiquitous motor controls. Coupled with the bandwidth offered by a technology like Ethernet, manufacturers are benefiting from

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longer do we see manufacturers looking for process control as a mere enabler of productivity and consistency. Rather, manufacturers today seek a more holistic approach encompassing productivity, energy-efficiency, consistency, simplicity, adaptability, etc throughout the lifecycle. Integration Another trend witnessed is in the form of solutions that combine motion controllers, drives, PLCs and human machine interfaces

INSTRUMENTATION & CONTROL

(HMIs) into more tightly integrated product offerings. The drive towards lower cost solutions, smaller footprint products and lesser system engineering content for motion applications fuels product innovation. The application of integrated motors and bundled control solutions is greatly increasing. The conventional distinct hardware components for motion control systems, PLCs, HMIs and general purpose input/output (I/O) are taking a backseat as new hardware/software solutions take centre stage. Pradeep Shoran, Marketing Manager, Kuka Robotics, says, “Newgeneration motion controls can easily be integrated into higher-level control structures. Axis interpolation, electronic line shafts, master-slave couplings are provided as integral parts of the new motion control systems. Besides, in newgeneration motion controls, everything from soft PLC to open connectivity (OPC) can be run on a single platform. Moreover, there is a free choice of Fieldbus.” He further adds, “With integrated soft PLC, the modern motion controller can also take over the control of the entire production cell. In addition, there are integrated safety functions such as the anticollision function, increased availability through Internet remote diagnosis, offline programming, etc. Data evaluation has become simple with new motion controls. There is also provision for optimal system integration from a single source.”

GOING WIRELESS Wireless technologies offer enormous benefits to the manufacturing industry. Wireless instrumentation provides more convenience to manufacturers. Karnik states, “Wireless technologies help in integrating existing instruments to new systems without the hassles of relaying cables and also make it feasible to progress to new instruments/measurements, easily interfacing to existing control systems. Similarly, wireless sensors offer huge benefits to the manufacturing industry.” Wireless sensors are an attractive option for the factory floor because they do not suffer from cable breakage. Today, wireless technology is being widely used to control instrumentation. By networking an instrument, one can increase the amount of information flowing to and from it, thereby allowing creation and use of maintenancerelated signals.

New-generation motion controls can easily be integrated into higher-level control structures. Besides, in such motion controls, everything from soft PLC to open connectivity (OPC) can be run on a single platform. PRADEEP SHORAN, Marketing Manager, Kuka Robotics

ADVENT OF DIGITAL TECHNOLOGY Control systems has benefited from the emergence of digital technology. Probably, the biggest impact of digital technology, yet to be fully tapped by the manufacturing industry, is the convergence of the largely discrete PLC and analog DCS. Karnik says, “This convergence has presented manufacturers with process control choices, hitherto unavailable in the discrete/ analog silos of the bygone era. Manufacturers can select the technology that best meets their current and future control system needs, without compromising on performance. Needless to say, today’s digital control systems, economically meet the control performance requirements of manufacturers, in terms of accuracy, flexibility, compliance, information and response times.” Increasing demand for more flexible and scalable devices in the manufacturing sector is compelling the instrumentation solution providers to innovate. “To meet the everchanging production requirements, manufacturing machineries should be flexible, scalable and to adapt mechatronic form. Smart devices unify the field of mechanical engineering, informatics and electrical engineering in modelling the technical elements and processes. In simple terms, the mechanical elements like gears, line shafts, cams in a conventional machine should be replaced by software solutions, which would make upgrading the system easy so as to suit the market demand,” says Shashikant Ghorpade, Senior Manager Motion Control Production Machines, Drive Technologies, Siemens. The solution will thus become compact, combining drive control, motion control and PLC logic in a single unit to control an entire machine.

Modern solutions also co-ordinate motion and logic control and handle other technology requirements pertaining to temperature, force and pressure control. Users also get the advantage of plug-andplay functionality with automatic component recognition.

MAJOR DEVELOPMENTS There have been significant developments in technology in the field of instrumentation and control. The online use of high-speed and high-capacity computers makes possible instant evaluation of plant status and offers new ways of displaying information to the operators. While providing real advantages, these technologies place new burdens on designers and licensing authorities, for example, by introducing possibilities of common mode failure (CMF). Requirements for software verification and validation are both new and important. Karnik avers, “Instrumentation technologies need to be leveraged for achieving numerous benefits. However, fundamentally, technology does not have a major impact on the measurement and actuation domains. The principles here still largely remain the same, though incremental improvements are seen. What is actually changing is the ability to generate intelligent information at the device/instrument level, the ability to access

Wireless technologies help in integrating existing instruments to new systems without the hassles of relaying cables and also make it feasible to progress to new instruments/ measurements, easily interfacing to existing control systems. PRADEEP KARNIK, Business VP – Industry, Asia-Pacific Operating Division, Schneider Electric

and use this information easily and the ability to leverage the computing capability at the device/instrument to perform control actions locally.” Emerging technologies like wireless, not only enhance information access, but also make system integration easier and economical.

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INSTRUMENTATION & CONTROL

Determining the Best Controller for Small System When choosing the type of control system for a particular application, there are many considerations that influence the decision. For instance, a DCS is designed for process control and a PLC is designed for machine or motion control. While either of these systems can be applied in the other domain, this can result in a loss of operational suitability. The checklists below are meant as a guide in choosing the right system for the job. Distributed control system (DCS) Deterministic control is important (ensures that logic is executed in a particular order at the same time, every time) Continuous control is required The application will be changing frequently In a batch application, the procedures will be changing (several times a year or more – adding new materials, changing formula parameters, changing order of steps) Operators of the system will have responsibility over a large area of the plant, often times all equipment required to make the product The application has events that occur even if control is stopped (reaction, heating, mixing) The system must be integrated with other applications and/or systems The application cannot tolerate any time delays Loss of operational view during production is unacceptable A highly available production system (controller, HMI, server,

BENEFITS Today, there are not many systems in the market that have single control manipulators or single integrated solutions for different functions. New motion controls, which will help integrate different functions into a single platform, have many advantages over the traditional solutions. Shoran asserts, “Earlier, using different control manipulators for various functions resulted in complex processes. It caused difficulties in controlling the flow of information and the flexibility was also less. In a single platform controller where integrated solutions are available, flow of information can be maintained easily. This also increases flexibility and performance efficiency to a great extent, besides offering larger number of axes and scalable systems.” Presently, there is an increasing focus on cost reduction, energy-efficiency, smaller footprint products, and the integrated solutions help achieve these goals simultaneously. Modern-day motion controls, sensors and drive controls help to meet energy-efficiency targets. Industry experts believe that focus on a complete machine design and engineering analysis, and use of energy monitoring and software modelling tools will enable further reduction

network, etc) is needed Example applications: Small to large batching processes (paint, PVC, dairy), water treatment, tank farms, etc. Programmable logic controller (PLC) High speed processing 90 per cent + discrete application (digital inputs/outputs) The application is predominantly machine/motion control The application will not change frequently The application can be represented easily by electrical relays, thus lending itself to ladder logic programming It is necessary to control single pieces of equipment or single workstations, that are loosely integrated at a higher level Operators of the application have responsibility over a piece of equipment only It is anticipated that the controllers for various pieces of equipment have minimal communication between them, and the communication won’t change much Stopping an entire controller to make a change to the configuration – adding I/O, changing a control strategy, etc, is not problemmatic The application has many areas, separated by distance, that each require only a small amount of I/O ( <100) Example applications: cement, metals and mining, automotive, packaging, pipelines, well-heads, etc.

in energy costs. New advancements are largely offering benefits of choice. “First, they present manufacturers with options in terms of selecting the most viable technology that meets their present and future needs. Choices result from the convergence of the legacy worlds, which are powerful enough while being flexible, scalable, open and

Courtesy: Automation & Control Solutions, Honeywell

collaborative. Second, these allow manufacturers to more holistically meet their operational needs. It is no longer just productivity and process control but also about compliance, responsiveness, energyefficiency and safety for manufacturers,” Karnik avers. Today, manufacturers are able to see the bigger picture and choose the most appropriate control system that enables them meet their needs.

FUTURE OUTLOOK

Smart devices unify the field of mechanical engineering, informatics and electrical engineering in modelling technical elements and processes. The mechanical elements like gears, line shafts, cams in a conventional machine should be replaced by software solutions, which would make upgrading the system easy so as to suit the market demand. SHASHIKANT GHORPADE, Senior Manager - Motion Control Production Machines, Drive Technologies, Siemens

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In the last several years, advancements in instrumentation and control systems offered greater performance efficiency and flexibility, thereby enhancing cost-efficiency for the manufacturing industry. Industry experts predict that the continuing trend will offer immense benefits to the manufacturing industry in the form of flexibility, cost control, energy-efficiency and faster delivery of data. In the future, when the need for a variety of system configurations increases, the modern instrumentation and control solutions will continue to offer unique architectural advantages. With advancements in the wireless technologies, more smart solutions will come into existence in a big way as a result of innovation and research in this field of engineering.

NEXT-GEN TECHNOLOGIES

INSTRUMENTAL FOR

‘INTELLIGENT’ MANUFACTURING

With increasing deployment of instrumentation & control devices and next-generation technologies such as sensors, graphical user interface (GUI) and laboratory instruments, the manufacturing sector is now witnessing a transformation in terms of production and efficiency enhancement. In addition, these devices are paving the way for better communication technologies, which is the need of the hour. Overall, the advent of intelligent systems will be instrumental in taking manufacturing to new heights. SHIVANI MODY he manufacturing sector is riding high on the growth wave, and as a result, undergoing a sea change. Owing to the benefits offered by the latest instrumentation and control devices in the form of enhanced performance, these devices are now widely adopted as a part of the overall system by the sector. Moreover, they are becoming smarter by the day and are capable of adjusting to

changes pervading the system. Added to this, the improving remote managing capability is also helping uptake of wireless devices, which are gaining prominence in the market. As a result of the vast improvements in commercial off-the-shelf products in the measurement & control segment as well as lower prices, companies are now adopting a combination of powerful tools rather than relying on conventional methods for making a custom design for every application. SR

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Venkatapathy, Head - Research (India & South Asia) & Senior Analyst, ARC Advisory Group, avers, “The instruments are turning digital, thus improving the diagnostic capability and enhancing the remote management technology. Ultimately, only the elements that are practical in the real world will prevail.” Some of the next-generation advancements in instrumentation and control technologies are discussed hereafter.

NEXT-GEN TECHNOLOGIES

TOWARDS BETTER COMMUNICATION

construction work, laser measurement systems are employed globally for collision With systems becoming complex due to protection. Sensors are also used in the use of multiple devices, the need for detection and error-checking applications.” speedy and better communication While there is scope for the use of RISING USE OF SENSORS technologies is on the rise. Information flow wireless sensors in industrial applications, One of the next-generation technologies and management of data are among the the industry still faces some challenges. gaining importance in the area of critical areas of focus for companies. This is These include multi-vendor equipment instrumentation and control systems is because they are now faced with questions interoperability, demand for industrialrelated to the number and type safety-rated wireless devices, of devices to be added onto a lack of adequate open Robotic systems are flexible, efficient and save huge system to improve the bandwidth, deployable network amount of time in the set-up process. Moreover, these communication technology in size & hopping challenge, systems enable accurate measurements, faster data the system. However, with the besides issues related to collection and evaluation. advent of next-generation constantly evolving standards. equipment, the communication Venkatapathy informs, “The sensors. The technological evolution of technology too is evolving to keep pace sensors, RFIDs, etc, will play a bigger role in sensors has made them smarter, smaller, with the growing requirements. discrete manufacturing, while in case of lightweight and economical. Wireless Venkatapathy explains, “Instrumentation process manufacturing, it needs to be sensors are widely used for various industrial and control equipment are used in both proven first. Placing sensors onto the system applications. The intelligent sensors can discrete & process manufacturing. Discrete will require more speed and bandwidth, as perform more operations than the manufacturing is transaction-oriented, while information has to flow quickly. It will be conventional ones and reduce the overall process manufacturing is done in real-time. difficult to put too many devices on critical system complexity. They are also easy to In process manufacturing, the most loops.” configure or programme. Further, the important factor is acquiring data at a faster INCREASING ADOPTION OF sensors are becoming smarter, as they are speed from the field, quickly responding to PLC SYSTEMS self-locating, self-regulating, self-calibrating the change and sending the information Programmable logic controllers (PLCs) are and self-powered. back to the field. This will lead to witnessing a growing demand in the Sridhara informs, “For any development of better communication manufacturing sector. Unlike generalinstrumentation & control system to technologies, improvement in quality and purpose computers, the programmable perform, feedback is important, considering even convergence of technologies— logic computers can be used to connect a closed loop system. This is the only wireless, the Ethernet and fieldbus systems with actuators and sensors that can mechanism that helps to ensure proper working closely together.” monitor and operate certain physical functioning of the process and reports any Open systems support high-level data changes or errors. Sensors used in the transmission from the field to the area system provide the necessary feedback. where people manage the systems in the The sensors have undergone an evolution field. Ethernet is used in the control network as well. Miniaturisation of sensors, remote of distributed control systems. It is a mature The PLCs have evolved from being or cordless controls, improved technology widely used for measurement communication technologies are some of systems in many capacities including general basic microprocessors to devices that the evolving trends in the field of sensors.” networking and remote data storage. Open can perform beyond the processing The use of wireless sensors and fibre multi-vendor systems can be built with activities. With better communication optics will definitely see increased adoption fieldbuses. Addition of control technology technologies and increased use of by the manufacturers. Currently, the to these data transmission technologies can open systems, they provide more majority of work related to sensors is in the offer solutions to problems faced by developmental stages and is yet to evolve. enterprises. functionality. As part of the system, Reliance on wireless sensors is increasing, Moreover, in the field of measuring they can even be managed remotely. as their use enhances the identification of instruments, performances and functions problems prior to actual system failure. have been improved. For example, S SRIRAM, Besides, implementation of bluetooth multi-loop controllers and small-sized Senior Manager – Business Development connectivity and use of laser measurement analysers are now being used by the & Marketing, Omron Automation systems for sensors have also taken place. industry to ensure error-free working and Pushpa Lopes, Assistant Manager – accuracy. A main reason for the popularity machines like electric motors, hydraulic Marketing, SICK India, states, “Presently, of Ethernet in instrument control is that cylinders, etc. India is witnessing an increased adoption of most companies and laboratories have PLCs can be applied for a wide range of sensors. This trend is driven by the existing Ethernet networks for instrument automation tasks, and their low cost is an automobile and steel industry. We have also control. added advantage. Most PLCs use a simple noticed the uptake of cordless sensors. In Sridhara TV, Optical Project Manager, GUI that can be easily handled by some cases, such as those related to Measurement Specialities, states, “The communication technology for instrumentation and control systems has immensly improved, resulting in increased adoption of the Ethernet.”

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NEXT-GEN TECHNOLOGIES

operators. Nowadays, the PLCs have set power has increased from 32 bit to companies have to quickly reduce time to standards, which increase their 64 bit. market and introduce new products for the interoperability in the system. In recent Kudtarkar says, “The instruments used industry. Many manufacturers are also years, PLCs have grown to accommodate for measurements are now faster and upgrading their instruments for faster features like sequential relay control, quicker. Nowadays, the users of the processes. These changes can be seen in all motion control, distributed control systems, instruments lack in-depth training, resulting sectors, especially automotive, energy, process control and networking. Modern in the need for less complex instruments. healthcare, etc. The latest technology will PLCs are developed such that their This has led to the evolution of GUIs, which help these sectors in undertaking testing storage facilities and data-handling have made these instruments user-friendly. processes, and adoption of automation will techniques along with their processing Also, the GUIs use the latest operating also rise in the near future.” speed and power are now platforms, that are powerful.” comparable to common The intelligent sensors can perform more operations MINIATURISATION OF desktop computers. than the conventional ones and reduce the overall DEVICES S Sriram, Senior Manager – Business Development & system complexity. They are also easy to configure or The size of the instrumentation Marketing, Omron Automation, programme. Further, the sensors are becoming smarter, & control equipment is reducing day by day. Presently, observes, “The PLCs have as they are self-locating, self-regulating, self-calibrating miniaturisation and reduced evolved from being basic and self-powered. weight are the norms for the microprocessors to devices that devices. A surface microphone can perform beyond the SMART MACHINES nowadays is available in the size of a processing activities. With better The concept of adaptive/smart machines thumbnail. Also, wherever possible, communication technologies and increased evolved from two perspectives in the handhelds are being increasingly used in the use of open systems, they provide more industry with regard to improving production manufacturing sector. Kudtarkar informs, functionality. As part of the system, they can quality as well as increasing machining “The shrinking sizes of devices provide the even be managed remotely.” throughput. The market for adaptive control same capability in less space, and the ADVANCES IN LABORATORY solutions has continued to expand over the reduced space usage can help companies in INSTRUMENTATION last eight years. A smart machine can make the long run.” As the pace of R&D accelerates, laboratories real-time decisions about manufacturing Venkatapathy believes, “Size reduction is face huge demands pertaining to providing processes. With proper adaptive controls possible mostly in embedded devices. In timely, accurate results at reduced costs. and better machine vision, operators can many cases, the sizes cannot be reduced Many of them are considering spend more time on creative work and less beyond a point. Eventually, we will see sizes implementation of automation in laboratory time on repetitive activities. The objective is that will be practical for use by the industry instruments. The increased pace of R&D to provide better information that will to some extent.” for new products, the need for better enable the management to achieve the goal On the same lines, Professor Christopher quality control in industrial settings and of manufacturing components better, faster Snowden, President, The Institution of government regulations have combined to and at lower cost. Engineering and Technology (IET), notes, create numerical targets for prototyping and Smart machines help in meeting users’ “The size of the devices is shrinking, mostly laboratory testing. Moreover, to survive in demands for increasing intelligence and led by the reduction in the size of the increasingly competitive environment, flexibility in control systems. Sriram says, semiconductors. Moreover, the size of R&D laboratories need to find ways to “Smart machines depend on a pre-defined transistors on a chip is as small as 30 million utilise skilled laboratory technicians to logic and work on a set programme, which transistors on top of a pin-head. Soon, we perform high-value tasks and reduce the makes sense of the input and output in the will see a semiconductor chip having 2 redundant, low-value tasks. Automation system. Using a PLC system connected to a billion transistors. Experiments are ongoing offers a solution to many of these robot, the machine becomes smarter and to use materials that can further reduce requirements and holds the potential to pay can do more than just transferring energy consumption and decrease the back more in less time. information.” size.” Robotics, along with automation, can BETTER PROCESSING POWER DEVICES OF THE FUTURE help in the process as well. Robotic systems AND ENHANCED GUI As the industry moves forward, the nextare flexible, efficient and save huge amount The software used in the IC systems has generation devices will see more adoption of time in the set-up process. Moreover, improved considerably. This has led to an by the industry. In some cases, these these systems enable accurate increase in processing power at the back devices will have to be tested and proven measurements, faster data collection and end, from 8 bit to 24 bit. This, coupled with for their capabilities. Moreover, the devices evaluation. In many cases, laboratory tests updated software, has resulted in improved need to be selected carefully based on their have reported that the set-up time has been graphics. The weight of devices has practical application in the processes. The significantly cut down by 90 per cent, decreased and the processing power has advent of smart and intelligent devices is all making the R&D process faster than before. risen exponentially. Currently, devices are set to take the manufacturing sector to new Ashok Kudtarkar, MD, Bruel & Kjaer, being introduced where the processing heights. believes, “With the rising competition,

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AUTOMATION TRENDS IN INSTRUMENTATION & CONTROL

MOVING TO A WIRELESS INFRASTRUCTURE The widespread reliance on networking in business and rising online services stand testimony to the benefits of shared data and resources. Wireless technologies advance these benefits by allowing users to access shared information without the constraints of a wired connection. They offer benefits in terms of productivity, convenience, and cost advantages over traditional wired networks, thereby enabling manufacturers to solve business problems and gain an edge over competitors. he emergence of a new competitive environment for industrial products and services is forcing a change in the way manufacturing enterprises are managed. And, with wireless applications revolutionising the way products are manufactured, it is expected that the worldwide market for such technologies in manufacturing will grow at a compounded annual growth rate (CAGR) of 26 per cent over the next five years. In addition, industry experts believe that the savings in installation costs will drive significant improvements in process automation. The past several years have witnessed numerous developments in industrial wireless technology. However, the challenge for companies lies in decoding this new

wireless world and choosing the appropriate solutions that will meet their requirements.

THE NEED Investments in wireless technology are imperative for strategic and business needs. For instance, the reasons for prioritising wireless applications in chemical plants include identifying applications that involve high energy and natural resource usage and optimising field worker productivity. With the availability of mesh network solutions, some wireless vendors still expected users to introduce wireless into their plants with small projects aimed at monitoring specific applications and eventually progress to the larger network. However, a surprisingly high number of users are showing interest in the larger networks at the first stage of implementation.

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This early enthusiasm is indicative of the wireless product evolution. The first generation of products had been sensorspecific and not designed to cover entire plants â&#x20AC;&#x201C; which was reflected in the smaller purchases. Today, the new generation of products is more appropriate for wider plant deployment and manufacturers are ready to take advantage of the same. The overarching applications of industrial wireless technology are aimed at attaining three major benefits namely safety, reliability and efficiency.

SAFETY The most obvious benefit of a wireless solution is seen in hazardous areas requiring manual measurements, where wireless sensors can reduce the need for workers to physically put themselves in danger in order

AUTOMATION TRENDS IN INSTRUMENTATION & CONTROL

of the plant, thereby increasing its efficiency. Corrosion monitoring can be upgraded to corrosion control, where this method previously relied upon visual inspection and sometimes required a unit shutdown. Companies typically want to take measurements at several points throughout a plant, to increase the value and accuracy of the information available. Wireless technology enables manufacturers to monitor multiple points without the cost of wiring and provide a more comprehensive picture of the plant. Equipment health monitoring can be expensive and limited to critical plant assets. This can leave huge areas of plant equipment with no real health monitoring beyond operator rounds and scheduled maintenance. Wireless can dramatically lower the cost of equipment health

deployment and the speed of installation. Wireless installations can take as little as a few minutes to deploy, reducing the time of approvals and processes that need to be followed for wired installations. Mobile operators can also become more efficient through the use of mobile technology to have a view of the entire process from the control room and also conduct rounds in the field. In collaboration with digital cameras, operators can visually inspect pieces of equipment for damage. The cameras transmit images back to the control room reducing the amount of time that needs to be spent carrying out rounds. Process efficiency can also improve, as additional measurements provided by wireless technology will enable operators to run their processes efficiently to improve yield and throughput.

Wireless technology has evolved radically into key systems for application in next generation manufacturing systems. In recent years, wireless technology has become more available, affordable, and easy to use. Wireless technology is still developing, and currently, mostly relies on advanced computer networks, the worldwide web and the Internet. to monitor data points. Less wiring also means less chance of a deadly spark. Apart from this, there are other innovative ways in which wireless technology can increase plant safety. Wireless technology improves safety by way of people and asset tracking capabilities. Through the use of various location technologies, new wireless solutions can enable managers to track employees on the plant floor. This capability is crucial in the event of an untoward plant incident, because it allows managers to better coordinate with emergency responders. This same tracking technology can be used to monitor the movement of hazardous equipment and materials, or even to interlock process steps with a verification that all personnel are in the appropriate place.

RELIABILITY Generally, equipment used in manufacturing plants will inevitably wear out and need to be replaced. However, effective monitoring solutions can help minimise and prevent the effects of natural wear and tear, and also increase plant uptime. Wireless applications can help to enhance reliability of functioning

monitoring implementation, allowing operators to effectively monitor a greater number of assets within the plant with a significant economic return. Monitoring of a larger number of assets allows operators to increase uptime while reducing unnecessary maintenance costs. An innovative benefit of mobile wireless solutions is the creation of â&#x20AC;&#x2DC;wireless workersâ&#x20AC;&#x2122;. By providing personnel with wireless solutions, their rounds can become entirely computerised, thereby reducing the possibilities of error and speeding up the transition of data from the field to the operator. Wireless workers can monitor more assets with greater speed and accuracy to improve plant reliability.

EFFICIENCY Increasing the safety and reliability of a plant will inevitably have a positive effect on the efficiency of the systems, and wireless can have a positive impact on the implementation, people and process efficiency. Increasing the efficiency of deployment immediately delivers cost savings. The cost savings associated with wireless implantation comes from both, the efficiency of

OTHER ADVANTAGES Despite the varied benefits, wireless can be a complex enabling technology, and hence requires careful research before implementation. If implemented in the correct way, this technology can deliver long-term benefits that directly impact a plantâ&#x20AC;&#x2122;s bottom line. Looking at the cost benefits, the example of an ethanol plant tank farm, where large tanks serve as holding stations paints a good picture. Due to the intense vapours emitted from ethanol tanks, these farms are considered an explosive environment and as such digital transmitters must be installed using explosion-proof or intrinsically-safe wiring, which raises the cost from about $25-40 per foot to around $80-100 per foot. In such circumstances, the installation of a series of wireless transmitters to monitor the tank level will prove an effective, and much more affordable solution. Without wiring to install, the implementation is much easier for vendors and less expensive for operators. Reduced installation costs, however, are just one of the visible benefits of industrial wireless solutions. Through such devices, companies can easily keep track of their

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AUTOMATION TRENDS IN INSTRUMENTATION & CONTROL

inventory. If installed in ethanol tanks, companies can also streamline and optimise operations by being able to accurately monitor tank-levels. Industrial wireless solutions can mean anything from a network of transmitters monitoring a single, specific application within a plant to a full-scale wireless mesh network deployed across an entire site to handle multiple applications.

MESH NETWORKS Wireless technology improves safety by way of people and asset tracking Mesh networks are considered the capabilities. most comprehensive of industrial wireless solutions. In general, there are Wireless mesh networks are also able to two types of mesh networks – sensor ‘self-heal’ in the event of network failure meshes and backbone meshes. Sensor due to an incident such as a backhoe meshes use a series of sensors to crashing into a node. In such situations, the communicate with one another in a signal is rerouted through other points to localised area. Backbone meshes involve ensure critical information such as process powered nodes that communicate with data is delivered. each other across wider distances, Multi-functional mesh networks are connecting various parts of a plant together. deployed for two main reasons, firstly based These nodes allow thousands of devices on the number of points a company aims to from field instruments, mobile worker monitor, and secondly, the high value that is devices and voice & video communication placed on reliable communications. Mesh to co-exist on a single network networks by definition offer multiple infrastructure. redundant paths; this increases

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reliability compared to non-meshing architecture. Finally, wireless technology has the advantage of being able to prepare a plant for the future, and this needs to be taken into consideration for any implementation. Companies need to consider whether they will use the wireless network for a single or strategic network, or whether they want to enable handheld devices to access data and interface with servers over a wireless network.

MAKING THE RIGHT CHOICE Many organisations are drafting wireless recommendations and standards as well as offering solutions to help wireless users find the best solutions for their applications. Deploying wireless technology with a defined strategy will enable an infrastructure that can provide significant benefits that go beyond avoiding the wiring costs – the right decision will help improve safety, optimise the plant operations and ensure compliance. Amol Chaubal, Product Manager - Wireless Solutions, Honeywell Automation India

Illustration By: Sanjay Dalvi

IT IN CONTROL SYSTEMS

SECURING

INFORMATION & OPERATIONAL NETWORKS Enterprises are widely implementing information technology for managing information system functions and operational technology for handling real-time operations. These networks are interconnected to ensure better visibility and information flow between operational assets and enterprise applications. But, inadequate security in these networks put the computing infrastructure at risk, thereby stressing on the need for securing operational networks. ecurity of a companyâ&#x20AC;&#x2122;s critical information technology (IT) and operational technology (OT) infrastructure is a key concern in todayâ&#x20AC;&#x2122;s world, as it is especially at risk from viruses, hackers, criminals and terrorists. A breach in IT systems can have significant social and economic consequences. Thus, organisations are making huge investments to protect their computing assets that manage information by deploying firewalls, anti-virus, intrusion detection and monitoring solutions. In fact, the spending on enterprise security information and event monitoring is increasing tremendously worldwide. With respect to the information aspect

of the business, IT and security personnel have done extensive work to secure the perimeter, networks and the hosts. They are increasingly being asked to extend the corporate IT strategy to address security of OT as well. Deployment of IT infrastructure products on the OT infrastructure seems logical. However, due to the unique nature of OT infrastructure, this approach may disrupt daily operations where availability and uptime hold priority.

DIFFERENCES IN CONTROL SYSTEMS Control networks and systems (OT) supervise the operation of large, complex and potentially dangerous physical processes. While some of the operation networks are specialised software running

on conventional computers, most are different. Some of the oldest control systems still use custom-built computers with custom operating systems or real-time kernels. Devices like remote terminal units (RTUs) and programmable logic controllers (PLCs) and those with conventional microprocessors can also be found at their core. However, these devices interact directly with a variety of physical sensors and actuators. PLCs often play an important role in safety as well, as they sample each input every few milliseconds, calculate and yield outputs at the same rate. And if an input exceeds the safety limit, a PLC can trigger an automatic emergency shutdown of the entire process or of the affected part of the physical process.

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IT IN CONTROL SYSTEMS

Securing operational technology networks requires a different paradigm than what corporate IT professionals have conventionally focussed on â&#x20AC;&#x201C; confidentiality, integrity and availability (CIA) â&#x20AC;&#x201C; in that order. For ensuring confidentiality, the most sensitive information should be protected from loss or disclosure. Availability may be compromised to repair the affected system, patch it and prevent access until confidentiality can be assured. Control systems (OT), on the other hand, and the personnel that run them, have different priorities. Industrial operations may be measured based on the availability or productivity of the physical process, but it is always in the context of availability, integrity and confidentiality (AIC). The process controlled by these systems includes collecting and disseminating data in realtime. It may involve potentially dangerous situations if the equipment is not running properly. Batch processes can run and collect data for many days, with a single batch generating revenues worth thousands or millions of dollars. These OT revenuegenerating assets must be continuously operational. Integrity of the data automatically collected from sensors is often transitory in nature and could be replaced by another measurement on the subsequent scan. The primary requirement is to ensure the accuracy and validity as it travels; thus, many networks address transmission over serial links with a slow speed. Although the information in an OT system or network can be confidential, protecting the confidentiality of the information is a lower priority than ensuring running of the realtime system and integrity of data. A major difference between IT and OT systems is that OT systems are often directly connected to pipelines, electrical grids, process equipment, chemical processes, etc. A security breach can have severe consequences, including loss of revenue, environmental damage, power outages and even loss of life. Therefore, in high-risk industries, such as oil & gas or chemical, a new paradigm of security is emerging â&#x20AC;&#x201C; safety first and foremost, followed by availability and then integrity and confidentiality (SAC).

SECURITY CHALLENGES IN CONTROL SYSTEMS NETWORKS Here are some of the problems pertaining to control systems:

Ways to ensure network security Recognition of the unique protocols related to network traffic so as not to cause unnecessary alerts Configuration of control system intrusion sensors to detect the known, good traffic and give an alarm regarding threats Careful design in adding intrusion detection sensors, so that they consume minimal CPU and network bandwidth to avoid disrupting time-critical operations Support for access control for remote devices such as PLCs, distributed controllers, etc. Old hardware and older, unpatched software and operating systems: Often, almost none of the components in a control system match the latest vendor patch level. The operations facility is unable to test new patches as soon as they are produced to ensure continued safe operation of the control system. Patches are applied slowly and carefully. For example, a test bed system might first be patched and then tested. Then, for each computer in the operational control system, a patch may be applied on one system in a redundant set, and that system is observed for some time. The process is not fast enough to keep pace with weekly or daily security patch releases, but over time, it may be enough to keep most of the control system within several months of current patch levels. No anti-virus running: Most control system vendors do not support their software on equipment with conventional anti-virus software running. Currently, a small set of vendors supports anti-virus, often for a small subset of their product line, but most do not. Further, for many operational systems, applying anti-virus after the fact, without the support of the vendor, can result in a malfunction of the control system. Plain text, unauthenticated communication protocols: Only the latest control systems applications routinely use secure socket layer (SSL). The use of non-transmission control protocol (non-TCP) and noninternet protocol (non-IP) is common. Control system components are specialised and focussed on real-time response that is fast enough to maintain the stability of a fastchanging physical process. Vendor default passwords: Passwords are often not changed, so that in case of emergency, an engineer, operator or technician can remember the password to

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a critical component to enable averting a possible catastrophe.

RISKS FROM THE NETWORK CONNECTION Earlier, IT and OT networks were completely isolated from each other and used different equipment, operating systems and communication protocols. While this is true to some extent, many OT networks have adopted IT solutions due to their cost advantages. Furthermore, companies have realised the wealth of valuable information contained in their supervisory control and data acquisition (SCADA), distributed control system (DCS), EMS or MES computers, so they have integrated the two networks to facilitate access to detailed production, inventory and other operational data throughout the organisation. If the IT and OT systems and networks are interconnected but not properly secured, a breach on the OT side can easily transverse to the IT side and vice versa. It is important to know who should be responsible for addressing this risk. Often, operations staff and plant engineers are aware of this risk and are interested in securing their control systems networks to ensure their safety. The mission of operations staff is to ensure safe, productive and reliable operation of the physical processes and any threat to the control system is a threat to the safe operation of the physical processes. In some cases, the staff may not realise the interconnectivity of these systems. Unless the IT team has a person with experience in OT control systems, the first reaction is to look at the problem as an extension of the enterprise security problem. Because of the scale and complexity of the networks they manage, IT departments generally select a few

IT IN CONTROL SYSTEMS

vendors, qualify their products and then apply them as corporate standards.

FOR A DIFFERENT LINE OF DEFENCE Corporate standards selected for enterprise IT networks do not meet the needs of OT networks. IT staff may have a tendency to look at control systems as just another computer, but treating the two types of systems as equivalents can lead to unexpected and even catastrophic results. The unique characteristics of OT systems and networks mean that many conventional best-in-class enterprise IT security solutions do not actually work on control networks. Further, they may impair or completely stop the operation of the system. For example, initiating a port scan on an OT network can have the same impact as a denial-of-service (DOS) attack. Installing the latest patch to fix a security hole may cause the control application to fail and force a line to shut down. When an anti-virus application checks for updates, it may impair the timing of responses to system health/heartbeat messages. This impairment is interpreted by the control system as evidence of a control system malfunction, which thus triggers a safety shutdown. OT control systems and supporting networks have unique protocols and traffic patterns. Conventional IT security components seeing unrecognised traffic may cause unnecessary false alarms or frequent alerts. Any new technology, procedure or other change deployed on OT networks must be reviewed to ensure that the change results in continued safe and correct operation of the physical process. Operations staff and control engineers are the experts on safety and availability of the control system and physical process. They must be involved in specifying technology requirements and in reviewing, testing and certifying the safety of new technologies & processes before deployment.

CRITICAL INFRASTRUCTURE WITH SAFETY Securing OT infrastructure from cyber threat can be achieved by adopting many policies, approaches and best practices by the enterprise, but the products deployed must be designed and optimised to work within the unique requirements of control networks. At an enterprise, the first solution often deployed is an electronic security perimeter (ESP) for OT network. IT and

operations should jointly define a demarcation boundary between the enterprise network and OT network. This boundary will protect the enterprise network from vulnerabilities in the control system devices without requiring the imposition of strict IT security policies that are inappropriate for OT networks, and protect the operations network from threats that arise on the enterprise network. The operations network should have no routine access to electronic mail or the Internet. Operations personnel need such access, but workstations with such access should be on the enterprise network side of the ESP. Ideally, the interface between the enterprise IT security zone and OT control system security zone should be a firewall or more modern ‘Unified Threat Management’ (UTM) device. This device is used at the edge of the control network to dynamically regulate traffic to and from critical OT systems, block viruses and intrusion attempts as well as provide secure connections to authorised external users. The device should be configurable for a variety of pre-planned lock-down responses based on current threat levels or routine maintenance. The second level of defence often deployed as part of a ‘defence-in-depth’ strategy is intrusion detection. These intrusion detection measures must be passive, with tight resource controls, and carefully introduced so as not to consume CPU, memory, network, disk or other resources, which could impair system performance. Network intrusion detection sensors must be able to passively monitor all network traffic within the security perimeter, enabling detection of any suspicious activity, including internally generated attacks, as well as one that may have circumvented the perimeter defences. The network sensors must be able to recognise the de facto protocols used by process control systems (Modbus TCP, DNP3, ODVA Etnernet/IP, ICCP, etc.) and generate alarms for logging and diagnosis. Host intrusion detection sensors, which reside in and secure the critical process control host systems, such as DCS workstations, SCADA servers, historians and substation routers, must be customisable for the control applications running on a specific control system. They should also be designed such that they have minimal impact on older SCADA and DCS workstations, which are often resource constrained.

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For the most effective management of the security environment, operations personnel should be able to access a central console that monitors and protects control systems from threats and vulnerabilities by collecting all event logs generated by devices within the plant, including the perimeter protection devices. A security event manager is a critical component, which provides IT-like visibility to control system networks, archives event logs, processes logs in real-time and generates alerts in case of suspicious behaviour patterns.

RECOMMENDATIONS FOR NETWORK SECURITY As organisations increasingly merge their IT and OT systems to support business requirements, the responsibility for securing all the important assets from cyber attack can converge as well. Companies can benefit from having an enterprise view across all security systems, but the products in the control world need to be optimised for fulfilling the unique needs of this environment. On the OT side of the boundary, technologies designed or certified for use on industrial networks should be selected. Also, passive technologies should be adopted. Data collection within the control system must not impair the behaviour or performance of the control system. Simple technologies should be selected, as corporate network administrators and call centre personnel may not understand the unique and complex systems on OT networks in an enterprise, though at each site, operations personnel understand the networks they maintain. Furthermore, one can consider outsourced managed security services to provide in-depth expertise and 24x7 coverage to ensure uptime and availability of OT networks. IT and OT personnel responsible for security should work together to devise the appropriate defence-in-depth strategy to protect all systems from cyber attack. Finally, it is important for the IT and control system engineers to have discussions on security and safety issues to gain more information on them. Security is a continuous process because threats and vulnerabilities are constantly evolving. Working together is the best way to ensure safety, reliability and security of mission-critical OT networks. Andrew Ginter, Chief Security Officer, Industrial Defender, Inc.

PUMPS & VALVES

PUMPS & VALVES: Gushing Ahead With Force ................................................................................76 MACHINE SAFEGUARDING: Enhancing Equipment & Worker Safety ...........................................82 CASE STUDY: Seepex Pumps In Fodder Processing - Transporting The Right Dosage At Stable Pressure ........................................................................87

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PUMPS & VALVES

GUSHING AHEAD WITH FORCE Owing to rapid industrialisation in the country, pumps and valves, which till a few years ago were considered as just any other products, have now become indispensable components of the manufacturing sector. This growth has been facilitated by technological advancements and innovations. However, there are some challenges that need to be addressed. By overcoming these roadblocks, and meeting the large global and domestic demands, Indian pumps and valves industry can pump in better prospects and gush ahead with force.

SUDHIR MUDDANA & SANDEEP PAI n India, the significance of pumps and valves industry is evident not only by the size and pace of the domestic and international demand, but also by the fact that it comes across as an outsourcing option for companies in the developed economies. The country is slowly getting integrated into the global pumps and valves supply chain. The world market for pumps is projected to reach $36 billion by 2010 from an estimated $33 billion in 2007. For this to happen, India has to play a significant role along with China and the US (together with Canada), the leading players in the pumps industry. Similarly, the valves industry is also flourishing rapidly with several national and international gas projects in the pipeline.

Y Buch, President, Indian Pumps Manufacturers Association (IPMA), avers, “The Indian pumps industry is expected to grow to $1.25 billion by 2020, fuelled mainly by soaring domestic demand from the water and power sectors, complemented by an increase in international exposure.” When asked about the role of the Indian pumps industry globally, Buch explains, “Over the past few years, domestic players have been looking to tap the huge global market. This has led to a growth in exports at around 10 per cent in the recent years, and more importantly, resulted in a gradual improvement in quality even amongst smaller players who are venturing in the global arena. Indian pumps are today exported to over 70 countries, including developing nations in Africa.”

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THE CRITICAL ROLE The industry has seen enormous growth from the time Kirloskar Brothers (KBL) established the first pumps and valves manufacturing company in 1888. Today, there are over 500 large and small manufacturers in the country that produce almost every type and size of pumps and valves for a variety of operations. It is not just the industrial sectors that are dependent on the pumps and valves industry, but it is also widely used in farming, gardening, residential and industrial water supply and transfer operations. In addition, sectors such as the thermal & nuclear power generation, hydropower and pumped storage power generation, oil and natural gas, refineries, fertilisers, lubricants and petrochemicals, mining and metal ore

PUMPS & VALVES

refining, steel, paper, utility, agriculture and irrigation, fisheries and technology manufacturing have benefitted immensely with the use of pumps and valves in their daily operations. With such a massive scale of the Indian pumps and valves industry, it is bound to play a vital role in the country’s overall economic growth. However, its stake in exports is small compared to other countries like China. Nitin Chalke, MD, Hydraulics Group, Eaton Corporation India, notes, “Currently, the Indian market for hydraulic equipment operating with hydraulic mineral oil fluid is estimated at $700 million and of this, 30-40 per cent constitutes the pumps & valves products. The demand for pumps and valves has maintained a steady rate of growth over the last couple of years, except during recession. In the coming years, it is expected to maintain the rate of around 10-12 per cent in the India Indian market.”

QUICK TAKE Indian pumps exporters have managed to carve a niche in the Middle East and African countries, where standards and conditions are akin to what is prevailing in India. Moreover, mergers and acquisitions are likely to catch momentum in 2010 and consolidate major players in the pumps industry. Indian companies are capable of competing with globally attractive quality and prices. However, more technological innovations in automation will help industries become highly competitive in international markets.

Out of the 1,60,000 MW generated in India, close to 40 per cent are being used in the industrial sector and pumps consume 20 per cent of this on an average, which is equivalent to 9,000 MW (considering 30 per cent transmissions and distribution losses). Conservative estimate of even 5 per cent savings in this would result in a conservation of about 450 MW energy. This can easily be has become the preferred destination for achieved by the use of efficient global manufacturers of pumps and valves. The key pumps and valves, besides THRUST ON QUALITY sectors that are major consumers of industrial pumps operating the equipment With an ever-expanding Indian comprise water handling/sewage treatment, oil & proficiently. market, it is important that the Moreover, pumping refineries, and power product quality is maintained for systems are central to water Indian companies to compete distribution facilities of globally. Experts believe that there is no municipalities. Inefficiencies in these systems in thermal power generation,” Buch adds. substitute to constant innovation and create serious distribution setbacks. ASE Another significant impact of the pumps implementation of new technologies, if the points out that pumping improvements that and valves industry is that it is making a goal of high quality product manufacturing range from lower cost measures like soft notable contribution to the environment by has to be achieved. starters for motors, trimming impellers way of saving power and water. Nevertheless, Indian companies (when pumps are over-sized) and reCONTRIBUTION TO manufacture some of the technologically winding motors, to higher cost measures ENVIRONMENT empowered products, which include like replacing inefficient pumps with efficient According to Alliance to Save Energy aerators, pre-rinse spray valves, and ones and installing variable speed drives are (ASE), Alliance for an Energy Efficient metering and electronic faucets. While Economy’s (AEEE) policy partner, between talking about the designs adopted by Indian 2-3 per cent of the world’s energy pumps and valves industry, Buch says, consumption is used to pump and treat “Indian technical skills and engineering The technology to optimise the water for urban residents and industry. aptitudes have shown good capabilities of pressure developed by pumps, Furthermore, ASE research shows that almost immediate absorption of the involved energy consumption in most water design, manufacturing and quality control depending upon the requirement, systems worldwide could be reduced by specifications and application engineering reduces power consumption. At at least 25 per cent through cost-effective needs. This gives a good picture of the higher pressure, water consumption efficiency solutions, thus showing the internationally competitive field already in tends to be more than that at lower or impact of pumps on environment. play in India.” Currently, in India the total installed The technical skills and engineering optimum pressure. In all, understanding capacity of power as on March 31, 2010, is aptitudes in Indians can also be proved by the system requirement can bring 159,398.49 mega watt (MW). A study by the popularity of field-rewindable and userabout reduced power consumption McKinsey estimated India’s power demand friendly wet motor bore well submersible along with efficient pumps/valves. to increase to around 315-335 giga watt pumps used in Indian markets. Furthermore, (GW) by 2017, if India grows at an average the Indian manufacturers have competently of 8 per cent during the period 2007-17. evolved motor designs to work against KOSHY CHERAIL, This would require a five- to ten-fold rise in vagaries of power supply, explains Buch. President, Alliance for Energy Efficient power production, entailing investments While Indian pumps and valves industry Economy worth $600 billion. is quick to adopt the latest technologies, it has also developed some impeccable designs that are known worldwide. “Some of the notable achievements of indigenous development and R&D include primary coolant pumps and sodium coolant pumps for nuclear power, large 2,250 mm deliverysize vertical turbine pumps and concrete volume pumps for cooling water circulation

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PUMPS & VALVES

STATS SPEAK There are over 500 pump manufacturers in India, with majority of them being medium & small-scale players. India produces nearly 2 million pumps per year for diverse applications. However, the market is still dominated by a huge class of organised and unorganised small and medium-scale companies, with only a sprinkling of large Indian players like Kirloskar Brothers, KSB and a host of multinationals. India has a huge demand from the agriculture sector that is satisfied by small and medium companies. It is estimated that the Indian pump industry is around Rs 40,000 million and is expected to grow by around 7 per cent in the medium run. Domestic players meet an estimated 95 per cent of the country’s demand. With inputs from Y Buch, President, Indian Pump Manufacturers Association (IPMA)

among other options for achieving energy and water efficiency. Manufacturing of efficient pumps alone cannot ensure reduction in water consumption. Mechanical seal instead of gland packing in pumps can also help to avoid leakages in pumps, thereby avoiding wastage of energy. Koshy Cherail, President, AEEE, says, “The technology to optimise the pressure developed by pumps, depending upon the requirement, reduces power No consumption. At higher pressure, water consumption tends to be more 1 than that at lower or optimum 2 pressure. In all, understanding the 3 system requirement can bring about 4 reduced power consumption along 5 with efficient pumps/valves.” 6 Furthermore, Cherail mentions, 7 “Of the 450 MW that can be saved 8 through efficient pumps and valves, 66 9 per cent will be from manufacturing 10 industries. This is equal to 297 MW. 11 Calculating with the lowest emission 12 rates of 0.8 tonne of CO2 per kW, we 13 are looking at reduction of 2,37,600 14 tonne of CO2 per hour.” 15 While the pumps and valves 16 industry in India possesses numerous 17 advantages for various industries, it 18 has to overcome some hurdles in 19 order to become globally competitive. 20

BOTTLENECKS As India is becoming a global manufacturing hub, major pumps and valves manufacturing companies of the world are looking at sourcing components from India. This is bound

to prompt the Indian manufacturers to upgrade products further to meet international expectations. However, the Indian companies need to maintain the cost factor to compete with MNCs. Another problem confronting the Indian pumps and valves manufacturers has been the unbalanced demand. Chalke explains, “India as a country has established its competency in the manufacturing capabilities. However, the shortage of

competent suppliers who can meet international quality and delivery demands is something, which we should improve upon.” Particularly for the valves industry, increasing raw material prices like those of steel are a cause of concern and have put pressure on the export margins of valves manufacturing companies. Additionally, duties and taxes levied on the products are making Indian valves uncompetitive in the global market. However, the introduction of value-added tax (VAT) has eased the situation a bit. Core sector growth will drive up volumes for valves manufacturers. Being an intermediate industry, the valves segment is completely dependent on the growth of the manufacturing sector in the Indian economy.

BRIMMING WITH BRIGHT PROSPECTS

With the availability of cheap and highly skilled labourers, India has become the preferred destination for global manufacturers of pumps and valves. The key sectors that are major consumers of industrial pumps comprise water handling/ sewage treatment, oil & refineries, and power with a market size of 35 per Sector Per cent cent, 45 per cent and 20 per cent By Value respectively. In most of these sectors, Agriculture 35 even valves are used to a great extent. Fossil fuels - oil and gas 6 Hence, the industry’s growth is Power - thermal 8 dependent on sectors such as the Power - nuclear 2 petrochemical, oil and power. Public water supply and sanitation 8 Fortunately for India, the coming Petrochemicals 8 decade looks favourable as there are Petroleum refining 4 huge investments planned in power Rural and domestic water supply 6 sector. Among others, the most Metals and mining 4 important is the nuclear agreement Pharmaceuticals 4 with the US, which will certainly help Fertilisers, insecticides, pesticides 3 the Indian pumps industry to touch Coal 2 new heights. Health, hygiene & cosmetics products 2 Moreover, the oil & gas industry, Construction 0.5 which is witnessing large investment Soaps, detergents and hygiene products 1 from both state-owned Oil and Natural Fire-fighting 0.5 Gas Corporation (ONGC) and also Sugar, beverages, dairies, food products 1.5 private players in the New Exploration Textiles 0.5 Licensing Policy (NELP) regime, is also Paper & pulp 0.5 expected to be a big demand driver for pumps. Paints, dyes and dyestuffs 0.3 In the future, apart from these 21 Cement 0.2 bigger sectors, one of the core sectors, 22 Others, including marine services,packaged 3 systems such as lubrication systems, petroli.e. irrigation, will create huge domestic dispensing, etc. demand for pumps and valves industry. TOTAL 100 “Arid states like Andhra Pradesh have Indian pumps market as per end-user industry: General distribution of pumps as embarked on massive irrigation per end-user projects, and thereby, companies like

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PUMPS & VALVES

Kirloskar Brothers are reaping huge benefits,â&#x20AC;? says Buch. Nevertheless, multinational funding agencies like the Asian Development Bank are also funding irrigation projects in

The global market for hydraulic equipment operating with hydraulic mineral oil fluid is estimated at $26 billion, of which Indiaâ&#x20AC;&#x2122;s share approximately stands at about 3 per cent. But, in the coming years, we expect both the global and Indian markets to further witness an increased demand. NITIN CHALKE, MD, Hydraulics Group, Eaton Corporation India

several Indian states. According to estimates, in the past six months alone nearly Rs 8,000-crore worth of orders were placed

India can be justified by the presence of companies such as Crane, Audco, Flowserve, Durco, AK, KSB, Spirex Sarco and Xomox. Nevertheless, even the Indian companies are looking for opportunities overseas and some of them have also made a good impact in the international scenario. Indian pumps exporters have managed to carve a niche in the Middle East and African countries, where standards and conditions are akin to what is prevailing in India. Moreover, mergers and acquisitions are likely to catch momentum in 2010 and consolidate major players in the pumps industry. Recently, leading Indian pumps manufacturer, Kirloskar Brothers, announced acquisition of controlling stakes in four companies. Experts believe that the Indian companies are capable of competing with globally attractive quality and prices. However, more technological innovations in automation will help industries become highly competitive in international markets. The next five years are most crucial for the Indian pumps and valves industries when it comes to proving their potential.

Indian companies manufacture some of the technologically empowered products, which include aerators, pre-rinse spray valves, and metering and electronic faucets. in the irrigation sector, where pumps play a pivotal role. This will provide a big boost to the pumps industry in the medium term. As a result of huge domestic market, India has attracted several international players to set up their base in India. As such, MNCs have a dual objective behind their motive for acquiring the Indian pumps and valves market, namely: Tap the vast local Indian pumps and valves market Make India their export-base for neighbouring countries like Sri Lanka, Pakistan and Bangladesh. The most important advantage of the entry of foreign players has been that they bring with them the latest technologies available, thus making the sector lucrative. MNCs today are approaching India as a huge outsourcing destination for valves manufacturing. The major reason being a large pool of technically qualified personnel, low manufacturing costs and a large Englishspeaking populace. The growth of MNCs in

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MACHINE SAFEGUARDING

Though there are several safety standards in place along with best workplace practices, it is an accepted fact that achieving zero risk situations is a daunting task. But, it is not completely impossible. Machine builders and operators can adopt machine safeguarding measures and minimise potential damage to workers, equipment and work environment.

Enhancing Equipment and WORKER t is true that ‘Safety is everyone’s goal’, but how many companies realise its importance and work towards achieving safety is anyone’s guess. Sound workplace practices are key to ensuring safety, as these can reduce the risk of injury not only to machine operators, but also diminish the possibility of accidental damage to machinery and other company assets, or

harm to the environment. Common industry standards acknowledge that there is no such thing as zero risk, but nonetheless provide guidance to machine builders and operators regarding risk minimisation. This is commonly referred to as ‘machine safeguarding’. Here’s a look at some key factors.

CONTROL INTEGRITY The most important step in machine

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safeguarding is evaluating the entire system, not just the electrical components to minimise exposure to unnecessary risks. This is because systems are rated based on the weakest link in the control chain. Several standards (including ISO 138491:2006, ANSI/ASSE Z244.1-2003 (R2008) and ANSI/PMMI B155.1-2006) define the control system as including not only input, sensing, and interlock devices, but also output devices such as pneumatic and

MACHINE SAFEGUARDING

hydraulic valves. Often, valve operations electrical-control fault, such as when a relay also actuates abnormally, there is no ‘back affect control integrity. The function of a might be stuck in the open or closed up’, and control integrity no longer exists. fluid control valve is similar to that of an position. The second abnormal condition is Double valves are appropriate for electrical-control relay, and therefore, is when a valve develops diminished pneumatic and hydraulic equipment anytime subject to the same rules for classifying performance, i.e. when a valve becomes when reliability is an issue. Typical safety integrity. Thus, properly specified sticky or sluggish. In these cases, the valve applications include E-stop, two-hand machine safeguarding systems include reaches the proper position, but slower control, light curtains, safety gates, provisions for pneumatic valves that shifting affects safe stopping distances or pneumatic locking devices for safety gates, should: precise timing. The ANSI B11.19- 2003 hydraulic brakes, air brakes, amusement Be functionally redundant Standard mandates a monitoring system rides, hoists, elevators, pinch-point Be monitored for faults (including that detects these conditions for critical applications, or any other application where diminished performance faults, which applications and the ANSI/PMMI B155.1 control system integrity depends on valve may lead to the loss of redundancy) standard requires diminished performance operation. without depending on external machine monitoring, if stopping time would be ENERGY ISOLATION controls or safety circuitry affected. Return to a safe position in the event of Energy isolation Lockout/tagout (LOTO) is An easy solution is to use a selfa loss of pressure or other such event another high-priority safety issue. Under monitoring, Category 3 or 4 valve, designed Be able to inhibit further operation upon standard LOTO, all energy must be to detect both conditions. The use of detection of a fault until it is corrected dissipated and machine-status verified double valves remained relatively unheard Have a dedicated, specific function reset before a worker can enter a protected area of for many years, except in a few select input, and should prohibit a of a machine. The standards reset by simply removing or define ‘de-energised’ as The most important step in machine safeguarding is disconnecting all energy sources reapplying pneumatic or evaluating the entire system, not just the electrical from the machine and ensuring hydraulic power Not reset automatically. components to minimise exposure to unnecessary no circuits contain residual stored Control reliability is generally energy. risks. This is because systems are rated based on the considered safety Category 3 or 4 For fluid power, this requires a weakest link in the control chain. as defined in ISO 13849-1/ manually operated energyEN954-1 Standard for all types of isolation valve that must: Have a secure and tamper-resistant circuits. This ISO standard regarding industries, such as stamping presses, which method of lock attachment Category 3 states “a single fault in any of first initiated control reliability requirements. Be located outside the protected area in these parts does not lead to the loss of the Double valves provide dual internal an easily accessible location safety function” and that “a fault shall be functions (redundancy), so that an abnormal Have a method for employees to verify detected at or before the next demand function of one side of the valve does not energy dissipation prior to entering the upon the safety function”. And for Category interfere with the overall normal operation. protected area 4, “an accumulation of undetected faults At the same time, the double valves sense Not be used in normal production shall not lead to the loss of the safety abnormal operation on either side of the Have a full-size exhaust port (ANSI/ function.” valve and then inhibit further operation until Providing control reliability with fluid PMMI B155.1-2006, CSA Z142-02) the problem has been corrected and the Be positive acting (only two possible power is not quite the same as with electrical valve deliberately reset. This sensing and positions) controls. For instance, plain redundancy in a inhibiting function is commonly referred to Be easily identifiable safety circuit requires the equivalent function as monitoring. Can only be locked in the off position of four valve elements, not just two. Two of Two standard air valves, whether in the four valve elements handle the inlet parallel or in series, cannot perform the ALTERNATIVE LOCKOUT function, while the other two elements same safeguarding function. By simply The ANSI/ASSE Z244.1-2003 (R2008) handle the stop function (energy release). incorporating two standard air valves into standard also addresses other lockout Many self-designed systems risk having the circuit, no provision is made to sense techniques, called alternative methods of hidden, potential flaws, which can lead to abnormal operation of one side of the valve controls. These systems can save costs and unsafe conditions because they are unseen, or, even more preferable, diminished improve machine uptime. But these unexpected, and therefore, excluded from performance such as slow shifting. methods apply only to routine, repetitive design and safety reviews. A good example In addition, there is no provision for tasks that are integral to the production is the spool crossover condition or ghost inhibiting further operation of the circuit process and are based on risk assessment positions of a valve, which are usually not until the valve is repaired. If one valve providing effective personal protection. A shown on schematics. actuates abnormally, the second one machine must have a standard lockout continues to function and redundancy is ABNORMAL CONDITIONS system for repairs and other tasks. lost. The circuit does not recognise lost AFFECTING VALVE SAFETY Alternative methods of control offer two redundancy nor would it halt operations as Two general abnormal conditions can affect time-saving advantages. First, it uses a single a warning that redundancy has been valve safety. The first is similar to an lock point (a remote, low-voltage system) compromised. Then, if the second valve

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MACHINE SAFEGUARDING

that simplifies and speeds up lockout, and enhances safety by avoiding the chance of a point being missed. The operator need not travel all around the machine to access various points to lockout or unlock operations. Such systems have electrical lockout switches, connected to the control system, at locations that require machine access, and incorporate appropriate safety valves for pneumatic and hydraulic lockout. The standard is also useful for tasks that are not routine, repetitive, or integral to production, but require power for, say, troubleshooting a control circuit. The new standard recognises that some risk is present with respect to certain tasks. In this case, the standard requires that the control system and valve controlling the non-isolated energy must be control-reliable, Category 3 or 4.

RISK REDUCTION There is no such thing as zero risk. Therefore, the standards require an assessment of all possible risks to determine the possible ways for most effectively reducing those risks. The best approach to risk assessment is as a team. One big change ANSI B11.TR3-2000 brought about is that both the machine manufacturer and user are responsible for performing the assessment. Some of the ways to avert risks are as follows: Hydraulic accumulator dump valves must be monitored or manually operated Pilot-operated check valves (PO checks), which are designed to hold a load in place and inherently trap pressure must be released during lockout procedures Use 3-position all-ports blocked valves that trap pressure Take measures to prevent hazard caused when a hose or tube fitting blows off Sudden surge of compressed air reapplied after LOTO cause cylinders to move quickly and subject the machine to shock. For all of these, and more, a complete analysis of the circuit should be taken to uncover potential hazards, even though those have never occurred in the past. The standards say if it can happen, it must be considered.

PROMOTING SAFETY STANDARDS To design a control-reliable circuit, the engineer must be able to break the reliability chain into links. Each link must represent a control device that meets the control reliability specifications listed above. If the device does not meet all these criterias, it is not considered a control device but only a component for integration into a circuit, thus requiring additional components or requiring even a redesign to achieve control reliability. Updating a system may not be difficult, if the electrical controls are already control-reliable. Because some valves have all of the monitoring logic built right in, there is no need to modify existing external control circuitry for valve monitoring. Simply replacing existing pneumatic or hydraulic valves with critical-application valves and properly wiring them into the system may bring the fluid controls into a control-reliable performance state. So, the next time a circuit is designed, it is important to remember that the ANSI, OSHA, ISO, and consensus standards apply to the entire control circuit from beginning to the end and ensure that the chain is not broken. Eric Cummings & Steve Boyette ROSS Controls, Troy, Michigan

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SEEPEX PUMPS IN FODDER PROCESSING

Transporting the RIGHT DOSAGE at STABLE PRESSURE Fodder processing plays a decisive role in the production of high-quality meat. It is transported through pumps to the barns. Some of these pumps had limitations related to carrying the precise dosage and maintaining required pressure. To overcome these limitations, a manufacturer of fodder systems used Seepex progressive cavity pumps that offered cost benefits, besides being service-friendly with low-maintenance requirements gricultural businesses have experienced huge growth over the last few years. Moreover, the rising demand for technical equipment used to rear livestock have gone hand-in-hand with this progress, as intensive livestock production calls for high quality and reliable feed supplies. In view of the fact that growth is always inseparably linked to added costs, companies are constantly on the look-out for innovative solutions to get these additional costs into a proper framework. Fodder processing is a relevant cost factor in cattle rearing businesses. Precise dosage of the fodder is of decisive importance for the effective use of fodder and for rearing high-quality meat. Ground or shredded grain mixtures are mixed to form a homogeneous, tough pulp in the mast of pigs, sows and piglets. The pulp is then transported through pipes to the dispersed fodder points.

BOTTLENECKS IN APPLICATION OF PUMPS The pipes need to be increasingly longer as the barns become larger. This means that the demands with respect to various applications using the pumps also rise. Centrifugal pumps, for example, which were once frequently used for this kind of application, have technical limits.

RESOLVING THE PROBLEM Pumps must be capable of transporting the tough pulp across long stretches with stable pressure and precise dosage. In this context, it should be simple to set the dosage quantity, while the maintenance costs should be as low as possible and the pump should be easy to clean. This is the only way to cut costs and at the same time achieve good results. A renowned manufacturer of fodder systems initially tested a Seepex progressive cavity pump, and it met the customerâ&#x20AC;&#x2122;s requirements with more than satisfactory results.

THE BENEFIT A few years have passed since then and

KEY FEATURES OF SEEPEX PUMPS Transportation across long distances with stable pressure Simple handling High dosage precision SIGNIFICANT COST SAVINGS High service life of the wear parts Low maintenance Service-friendly.

Seepex pumps in the central fodder kitchen during the distribution of the fodder pulp from the mixing containers in various pipes

PROBLEM Pumps used for fodder processing had to be capable of transporting the tough pulp across long stretches with stable pressure and precise dosage. The process of setting the dosage quantity needed to be simple, with low maintenance costs and enable easy cleaning of pump. SOLUTION Seepex progressive cavity pumps provided good results in terms of addressing the dosage and pressurerelated issues and enabled the operators to save costs. Moreover, the employees had less work as the pumps belonged to the low-maintenance pump category. several hundred pumps are now in use. All pumps work reliably and without any noteworthy malfunctions. The operators of the barns have never regretted their decision to use Seepex pumps and have saved a lot of money. The good value for money ratio, guaranteed by the long service life of the Seepex wear parts is an added advantage. The benefits are such that it meets the expectations of one and all, be it the operators, who are able to make huge cuts in costs; the employees, who have less work with the low-maintenance pumps, and finally the consumers, who appreciate the good quality of meat. Courtesy: Seepex

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CHIEF EXECUTIVE, SPECTRIS PLC

NVIRONMENTAL ISSUES â&#x20AC;&#x201C; A GROWING CONCERN AMONG ORGANISATIONS

Presently, organisations are seriously contemplating environmental issues and are taking necessary steps towards improving their products and processes. Large companies are now focussing on reducing their carbon footprint and ensuring that their products are environment-friendly. Even in niche segments, organisations are considering noise as a pollution factor and concentrating on various aspects pertaining to sound and vibration. Sound has an important social aspect and its measurement is carried out to monitor the impact of noise pollution on people at the workplace and in surrounding habitats. As a growing concern, companies need to address issues related to noise by measuring and analysing it correctly. Moreover, changes are called for effective reduction of noise. In bringing about this change, strategies of a company and latest equipment will play a supportive role. Some of the major industry verticals viz, the automotive & auto components

THRUST ON R&D WILL

INSTRUMENTATION & and aerospace community globally are now aware of the implications of noise and are paying attention to this factor. It has brought about many changes in the design element as well as materials used for manufacturing. The advancements in technology aim at addressing

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CHIEF EXECUTIVE, SPECTRIS PLC

“As a growing concern, companies now need to address issues related to noise by measuring and analysing it correctly. Here, strategies of a company and adoption of latest equipment play a supportive role,” emphasises John O’Higgins, Chief Executive, Spectris Plc, in an interview with Shivani Mody. Excerpts... the environmental concerns to a great extent. Once the industry leaders incorporate the changes, it is bound to impact the ecosystem and eventually benefit the society, leading to a cleaner, greener environment.

train – Japan’s high-speed railway – while it travels through densely populated areas. Presently, efforts are being taken to develop the next generation low-noise trains, which would be possible by focussing on the difficult task of reducing the aerodynamic noise. The sound & vibration measure and analysis systems are being used in wind tunnel tests to detect the aerodynamic noise sources of models. This data collection and analysis has enabled improvements to be made to the design of the train to reduce noise. One of the changes in its design is that now it has a long nose cone to the power car and an innovative wing-shaped pantograph, which takes the current from the overhead lines and helps in reducing wind resistance at high speed. While moving at a high speed, this design will reduce the noise produced.

The production of new generation cars is forcing companies to invest in the latest sound & vibration equipment for measurement. In India and worldwide, organisations are investing in the noise source identification systems as a part of their infrastructure to reduce the overall noise.

NEXT GENERATION DESIGNS – LOOKING TO REDUCE NOISE Taking into account the fact that noise is a pollutant both at the workplace and residential areas, efforts are on to control it or reduce it to a minimum level. Rather than modifying existing products, manufacturers are focussing on the initial design of products as the first step. For instance, when considering the various parts of a car, it is obvious that the engine makes the most noise. Nowadays, manufacturers are experimenting with innovative designs of engines in order to reduce the overall noise produced by a car. Added to this, manufacturers are also concentrating on R&D in design to create next generation body structures for the automobiles. The entire body of a car is being designed in such a way that it will reduce the overall noise.

TRENDS SUPPORTING GROWTH OF INSTRUMENTATION & CONTROL (IC) EQUIPMENT The automobile and aerospace sectors are among the fastest growing verticals globally and even in the developing markets. To cater to their

FUEL THE GROWTH OF CONTROL EQUIPMENT Further, in the area of new designs, complex structures are being simplified, which will help in reducing the noise element. These experiments are not limited to cars, as similar research is going on for developments in trains, aircraft, two-wheelers and the overall buildings and infrastructure. Some countries have already adopted the latest designs and are reaping benefits. For example, in Japan, the norms for noise and vibration levels are strictly regulated. This is a major concern for the bullet

demands, companies need to accelerate their production process and get products to the market in no time. These trends are resulting in an enormous need for instruments that can help them measure and analyse products accurately. The measurement needs to be quicker and the tools need to be easy to use. Globally as well as in the Asia-Pacific region, there has been an increase in transportation – be it via road, rail and air. There has also been an increase in the marine transportation segment. Today, not just the products, but also the overall processes along the chain need to be critically measured and analysed. For example, for an aircraft,

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CHIEF EXECUTIVE, SPECTRIS PLC

the sound & vibration can be measured and analysed during take off, & vibration levels by undertaking measurement and analysis. This will landing, while moving on the driveway, and its impact on buildings, play a major role in controlling and reducing noise pollution, which etc. This can give valuable information for future development of will immensely benefit the environment. products and construction of buildings, which can reduce the noise The production of new generation cars is forcing companies to pollution in the long run. invest in the latest sound & vibration equipment for measurement. In With rising competition in the growing markets, we see more India and worldwide, organisations are investing in the noise source thrust on research and development, which will fuel the growth of IC identification systems as a part of their infrastructure to reduce the equipment. As lab experiments and prototypes grow in numbers, it overall noise. For instance, many companies like Maruti Suzuki that will become necessary for use India as their export base The automobile and aerospace sectors are among are working in close organisations to have IC equipment as part of their R&D the fastest growing verticals globally and even in collaboration with partners, set-up for measurement, the developing markets. To cater to their demands, using advanced systems for analysis and testing. sound and vibration companies need to accelerate their production process measurement and analysis. LUCRATIVE INDIAN Generally, the norm for and get products to the market in no time. These trends MARKET airports is to have minimum are resulting in an enormous need for instruments that The Indian market is growing noise and there needs to be can help them measure and analyse products accurately. proper equipment to analyse with steady increase in exports. The measurement needs to be quicker and the tools need the same. In India too, with One of the emerging growth verticals in the country is the noise becoming a concern, to be easy to use. energy sector and it has opened noise monitoring is gaining up new avenues for our company, as the products in the energy importance. Currently, experiments are on at the Mumbai airport to sector are being examined for the sound & vibration levels. In use the airport noise monitoring systems and take corrective action addition, the steel industry too offers a plethora of business to control noise. opportunities for the company. Sound & vibration measurement and analysis is fast becoming ADVANCEMENTS IN TECHNOLOGY In terms of technology, the hardware â&#x20AC;&#x201C; the product itself has evolved critical in steel companies and this spells good demand for such over the years. The devices have become more accurate, userequipment. This is not all; equipment is needed in the education sector friendly and compact in size. For instance, a surface microphone can as well for sharpening technical knowledge and skills of students. The look as small as a 10 cent coin and is used by companies like Airbus knowledge-based industry is also progressing with a surge in hi-tech as well as some of the companies in India in both the aerospace and applications. This will lead to the need for sound & vibration equipment automotive segment. For monitoring purposes, the use and feel of in R&D activities. Apart from these, as mentioned earlier, auto and instruments is nowadays gaining importance. aerospace industries are seeing huge growth, both in the international Currently, customers have to adhere to strict delivery schedules, and national markets. All these put together will fuel the need for and hence, there is a need for faster measuring equipment. As people sound & vibration measurement and analysis in the near future. Spectris develops and markets productivity-enhancing using the instruments have limited training and experience, the instrumentation and control systems. Having sales of ÂŁ787 million in equipment need to be simple to operate. This also puts emphasis on 2009, the company employs around 5,700 people worldwide. As a proper support and service requirements. Added to this, tools for complete end-to-end solution provider, the company is looking at measurement and analysis are becoming reliable, easy to calibrate value-added integration through a systematic and organised approach. and accurate. In order to leverage the opportunities, it will invest in regional FUTURE OUTLOOK organisations and as & when required the acquisition route will be The technology, both the hardware and software for measurement adopted, depending on the right fit of solutions. and analysis, is evolving at a fast pace. One of the areas where Our total product development in India is in the form of embedded technology is advancing is in miniaturisation of sensors and new software development. Majority of our work is outsourced to Indian communication techniques. The power capability of these devices service providers and we closely follow the development of certain has improved considerably and they are more power-efficient. The verticals such as the energy sector. We see major investments in the measuring techniques too have improved and the standards of pharma and life sciences verticals, which are indicative of the growth measurement and analysis are being raised to the next level. potential in the country. Our range of equipment is well-suited for Further, the industry is leveraging the power of IT in terms of measurement, analysis and testing of products and molecules in the measurement and analysis of sound & vibration. Also we see pharma industry. enormous use of handheld devices in the industry, which will become FOCUS ON SOUND & VIBRATION prevalent in the future. MEASUREMENT AND ANALYSIS IN INDIA Currently, with increasing transparency/visibility and accessibility, In India, we see growing awareness regarding the harmful effects of huge amount of data and information is available for in-depth analysis. noise, and manufacturers are factoring the same while undertaking This data needs to be compiled and then interpreted properly for production of various goods. But the industry still has a long way to better and informed decision-making. The measurement, analysis go. and testing instruments will play a much larger role in this process and As a beginning, the auto industry needs to closely monitor sound will become supportive tools for organisations.

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ROSUB 6000

TOUCHING THE

HEART OF OCEAN

With the increasing demand for expertise to perform multiple deep sea operations for mining and oil & gas industry, the successful development of ROSUB 6000, a Remotely Operated Vehicle, has lifted Indiaâ&#x20AC;&#x2122;s potential and credibility on the global map in research competency. This deep sea technology, developed by National Institute of Ocean Technology, Chennai, is a first of its kind in India and has opened up sea of opportunities to explore the vestal offshore full of extremities.

SUMEDHA MAHOREY

Launch of ROSUB 6000 and TMS

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ROSUB 6000

The launch in process from the deck of TDV Sagar Nidhi at the PMN site, Central Indian Ocean

t a depth of 6,000 m in the vast Indian Ocean, the deep sea opened up an absolutely untouched expanse for the exploration of oceans, in India, in April 2010. An unmanned work class remotely operable vehicle â&#x20AC;&#x201C; ROSUB 6000 â&#x20AC;&#x201C; 2.53 m in length, standing tall at 1.8 m with a weight of 3,700 kg in air, has been successfully developed and tested by the National Institute of Ocean Technology (NIOT), Chennai, under the Ministry of Earth Sciences, Government of India, in association with Experimental Design Bureau of Oceanological Engineering, Russia (EDBOE), for deep ocean exploration in the Indian Ocean.

PROJECT INITIATION Living and non-living resources are abundant in oceans, which cover 75 per cent of the earth. In order to meet the future demand of these resources, a programme to harness these resources from the oceans was initiated by Late Prime Minister Indira Gandhi during the 1980s under the Department of Ocean Development

Brief Specifications of ROSUB 6000 Diving depth: 6,000 m Length: 2.53 m Height: 1.8 m Weight: 3,700 kg in air (-20 kg in water) Payload: Up to 150 kg Propulsion: Electrical thrusters Power: 6.6 kV, 460 Hz Cameras: 7 in number (Colour and B&W) Manipulators: 7 function & 5 function Lights: 8 Lamps Speed: 2 knots Navigational equipment: INS Doppler Velocity Log Depth sensor Sound velocity probe Forward & Bottom looking sonar

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ROSUB 6000

(now Ministry of Earth Sciences, Government of India). As a part of technology development for the detailed observation of sea floor and to support future exploitation strategy, a Remotely Operated Vehicle (ROV) concept was initiated at NIOT during the year 2002.

THE NEED The boom in Indian offshore activity and industry has defined the need for technological innovations, in the form of ROVs, which can work under the deep sea conditions and perform exploratory and maintenance activities ROV undocking from the TMS at 5,280 m depth as well as play supportive role for the multiple interests of the offshore mining and applications on-shore, having a number of the oil & gas industry. joints, a rotating wrist and a hand-like claw.

WHAT ARE ROVs?

DESIGN DEVELOPMENT

ROV is essentially an underwater robot that allows the vehicle’s operator to remain in a comfortable environment while the ROV works in deep sea. The complete ROV system consists of the vehicle, which is connected to the control van and the operators on the surface by an umbilical cable, a handling system to control the cable dynamics, a launch system and associated power supplies. The umbilical carries the power and the command & control signals to the vehicle and sends the status and sensory data back to the operator’s topside. In many cases, the umbilical includes additional strength members to allow recovery of heavy devices or wreckage.

The work on ROV design had commenced during 2004 and subcomponents were realised during 2005. The ROV assembly and integration was initiated in August 2005 and the first sea trial was performed during October 2006. After realisation of Technology Demonstration Vessel (TDV), ‘Sagar Nidhi’, during January 2008, deep water sea trials were performed in stages, from 1,000 - 5,289 m from onboard the vessel. It took six years to develop this vehicle from design to deep water qualification sea trial. The ROV was designed based on the literature available with NIOT on developing

ROSUB 6000 It is a Remotely Operated SUBmersible (ROSUB), which consists of a Work Class ROV, Tether Management System (TMS), Ship based Launching and Recovery System (LARS), Power transmission and Data telemetry system, Integrated Navigation System (INS), and Control and operational system (software). The submersible is also equipped with multifunctional tools and sensors for offshore applications and is rated for operations at the depth of upto 6,000 m. The submerged weight of the ROV is compensated by buoyancy packs made of syntactic foam fitted to the upper part of the frame. It is fitted with a five-function robotic arm, used to accurately position the ROV by holding on to a support, and a sevenfunction manipulator is then used to perform assigned robotic tasks. The manipulator is similar to those found in various industrial

Indian industries have expressed their interest in developing and using the ROVs at various depths and operating capabilities. Based on the user needs, ROVs can be built in a timeframe of two years. DR ATMANAND, Director, NIOT

underwater systems such as underwater crawler and the discussion with the joint partner from Russia. Providing insights on this critical project, Dr GA Ramadass, Project Director, Submersibles & Gas Hydrates, NIOT, deliberates, “After completion of design concept discussion

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with Russian counterpart, all subsystems of ROV were realised, integrated and validated at NIOT premises. The Russian counterparts provided inputs for ROV assembly, mounting arrangements and pressure cases. However, mechanical design analysis, hydraulics, electrical systems, electronics, sensors, deployment and control software have been developed indigenously by NIOT engineers and scientists. Many components were procured from the international market as per NIOT design and integrated to examine the system functionality in deep oceans.” Till date, ROSUB 6000 has undergone 12 dives from the TDV Sagar Nidhi of NIOT, which has been used as a platform for all deployments and retrieval of ROSUB 6000 for deep water qualification.

TRIAL RUNS The cruise on board Sagar Nidhi, for its highest depth qualification, began its journey from Mangalore on April 1, 2010, after completion of all the preparations for the trial run. ROV trials were conducted at different depths during the cruise up to a maximum depth of 1,250 m. Oil in the pressure compensators was topped up and minor corrections in the electronics in the ROV and TMS pressure cases were made during these trials. The site for the trials – Central Indian Ocean Basin – was chosen based on the extensive work carried out by National Institute of Oceanography (NIO). Dr Atmanand, Director, NIOT, who was involved with the ROV design in its initial phases, elaborates, “Based on the inputs provided by NIO, the ship was positioned and ROSUB 6000 was deployed for exploration at Central Indian Ocean Basin, which is about 2,000 km south of KanyaKumari, with the nearest land at a distance of about 500 km. The ROV was successful in reaching the maximum depth of 5,289 m. This is for the first time that any ROV has gone beyond the depth of 5,000 m in the Central Indian Ocean Basin.”

INITIAL HURDLES First trial at 5,000 m: The vessel reached Central Indian Ocean on April 12, 2010 and conducted the initial trials upto 1,250 m depth. The crew however, could not conduct the trial run due to rough sea. Dr Ramadass points out,

ROSUB 6000

“After waiting for the weather to improve, the first trial was conducted on April 14, 2010, at a water depth of 5,290 m. An average descent speed of 25 m/ min was maintained. All systems were tested at 50 m and 3,000 m water depth before reaching 5,000 m. ROV reached the maximum depth of 5,256 m where the pressure would be of the order of 500 bar.” However, the ROV was retrieved back before reaching the sea bed, as the crew noticed technical difficulties in the ROV. After retrieving the ROV to the deck, it was prepared for the retrial on April 17, 2010. Second trial at 5,000 m: The ROV was redeployed at the same location on April 17, 2010, at 0800 hrs. It reached the sea bed at a depth of 5,289 m at 1100 hrs. During this trial, the ROV was successful in capturing the video pictures of the sea bed. After capturing the videos, it was Retrieval of ROSUB 6000 after the dive lifted to an altitude of 10 m and connectors, power house comprising stepreleased from the TMS. ROV up transformer, high-frequency drive, etc. multibeam sonar was switched on after for 6 hours of continuous operation and the undocking the ROV at 5,280 m water control software and data acquisition depth, bathymetry data was collected along systems in control console. with back scatter data. After data collection was complete, the ROV was successfully RESULTS docked back to the TMS. The trials proved to be a major success as Dr Ramadass avers, “As a part of the all the systems of ROSUB 6000 were bottom investigation, ROV was lowered to found to be in full working condition below the sea bottom twice along with the short 5,000 m depth, where 500-550 corer. After retrieving the ROV to the atmosphere pressure can be experienced surface, it was noticed that two samples of in pitch darkness. The ROV was also poly-metallic nodules were collected in the successful in performing at its maximum short corer and the finer sediment had capacity for about an hour amid these been washed away during retrieval.” conditions. Dr Ramadass asserts, “The SYSTEMS QUALIFIED scientific payload of ROSUB 6000 such as Multiple systems, which include ROV frame forward and bottom looking sonar, oxygen, and syntactic foam, TMS, robotic arms, conductivity, salinity, temperature, sound inertial navigation system, sensors, pressure velocity sensors, etc functioned satisfactorily compensation systems for thrusters, pan & and logged continuous data throughout tilt units, etc. were tested and qualified at the trial.” Confirming the results, Dr Atmanand the depth of 5,289 m during this trial. avers, “All the systems of ROV have been The ship based systems, which have tested for their functionality and depth rating. been qualified for long-time operation The post-dive check revealed that the ROV during this trial are Launching and Recovery is in full working condition. Thus, the System (LARS) for lowering ROV from ship objective of qualifying the ROSUB 6000 at to 5,000 m water depth at the wind speed Central Indian Ocean Basin site at maximum of about 17 knots in sea states 3 & 4, 7,000 depth available has been achieved.” m umbilical cable with power & fibre optic

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EXPERTISE AND HUMAN RESOURCES Stressing on the importance of this innovation and the expertise desired to handle such operations, Dr Atmanand states, “NIOT ROSUB programme also aims at developing expertise in Deep Sea Technology, which is rare in our country. In the process of developing the vehicle, many techniques like pressure compensation, precision underwater navigation, power conversion, control loops, control and data acquisition have been learnt and mastered. NIOT has developed a team of qualified engineers and scientists who can employ these techniques in the future endeavours of NIOT. Thus, the country has made great strides in this area of engineering.”

SCOPE OF ROVs ROVs have multiple applications in the offshore mining as well as the oil & gas industry. These include multifunctional tools and sensors for offshore applications, deep ocean mineral exploration, seabed imaging, gas hydrate exploration, pipeline routing, submarine cabling, well head detections, sampling, etc. Of late, ROVs are also put to use for maintenance and repair activities offshore. The ROSUB 6000 has been specifically developed for the deep ocean exploration at polymetallic nodules site in the Central Indian Ocean Basin, gas hydrates in the Bay of Bengal and the hydrothermal vents in the Arabian Sea. Many Indian companies, existing as well as those foraying into the offshore mining space, are now emphasising on the acquisition of this kind of technology for their specific requirements. Highlighting the fact, Dr Atmanand avers, “Indian industries have expressed their interest in developing and using the ROVs at various depths and operating capabilities. Based on the user needs, ROVs can be built in a timeframe of two years.” With the successful ROSUB 6000 tests, a completely new avenue has been unveiled for deep water scientific exploration as well as the oil & gas industry for furthering its horizon to the limits of the vast ocean. Image courtesy: National Institute of Ocean Technology

GLOBAL MANUFACTURING COMPETITIVENESS

CORRELATING DIVERSE FACTORS TO ATTAIN EXCELLENCE Manufacturing competence building at a national level is a complex process. As organisations expand their global manufacturing footprint, they need to consider the multiple factors that underpin the competitiveness of a country. To better understand the dynamics of the overall manufacturing competitiveness, it must be examined by way of two major, inextricably linked forces – market and government. Although each country has its advantages and disadvantages, the competitive dynamics has a deep correlation, as per the findings. he classic factors of production – labour, materials and energy – are the most important drivers of global manufacturing competitiveness that form its ‘foundations’. Moreover, these factors are primarily driven by market forces, though they can be greatly influenced by government policy. In addition, the availability of talented people also drives manufacturing innovation and influences its overall competitiveness. These are the findings of a survey of manufacturing executives at a global level. The next four drivers of manufacturing competitiveness are ‘contributory’ government forces: economic, trade, financial and tax systems; the quality of physical infrastructure; government investments in manufacturing and innovation; and the legal and regulatory system. In fact, after the key factors of production, government forces have the most significant impact on the competitiveness of the manufacturing sector in a country. Environmental, institutional and infrastructural elements also help to shape and define the competitiveness of a nation in a concrete manner. The final three drivers, as rated by manufacturing executives are more ‘localised’ – the supplier network; the dynamics of the local business environment, including the size of the market opportunity and the intensity of local competition; and the quality & availability of healthcare. While these three final drivers appeared at the bottom of the list, they were deemed to be significant considerations in the overall competitiveness equation of a country. Thus, the three clusters of drivers – foundational, contributory and localised – are all necessary conditions of country-level manufacturing competitiveness.

DRIVERS OF MANUFACTURING COMPETITIVENESS Following are the drivers of global manufacturing competitiveness with regard to their relative importance to a nation’s progress: Talent-driven innovation Clearly, this driver goes beyond classical economic notions of low-

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cost inputs or the modern view of manufacturers chasing ‘cheap labour’ across the globe. In contrast, the most important competitive driver identified in the survey – talent-driven innovation – comprises both the quality and availability of a country’s intellectual pool. This includes skilled workers, scientists, researchers, engineers and teachers, who collectively have the capacity to continuously innovate and, simultaneously, improve production efficiency. Although difficult to measure through conventional indicators, the innovative capacity of a country depends largely on the quality of its human capital and supporting technology and business processes. Studies revealed that acquiring and developing the right talent is viewed as the most important practice within an organisation to make a company innovative and improve the overall competitiveness of the country. Cost of labour and materials Labour and raw materials are two major factors of production that have been an important consideration for manufacturing competitiveness since the dawn of the industrial age. The overall cost of labour includes those related to development, compliance and employee benefits, and the total cost of materials includes logistics costs and material availability. The historical roots of industrialisation confirm that manufacturing managers have actively sought efficiency in production by reducing labour and materials costs. Today, the wellknown just-in-time production system characterises these efficiencies in terms of improved worker utilisation and reduced inventories. Not surprisingly, the relative costs of labour and materials within a country will continue to drive its manufacturing competitiveness at least in the short term. For example, outsourcing of production is mostly associated with low-cost manufacturing capabilities and priorities. However, companies are finding that in their relentless chase around the world and outsourcing of low-cost labour, they can lose long-term leverage and internal competencies required to play the competitive game at the next level. Energy costs and policies Clean and reliable energy is an ever-increasingly important factor of

GLOBAL MANUFACTURING COMPETITIVENESS

production for all industrial sectors. As energy becomes scarce and countries struggle to attain energy security and independence, the costcompetitiveness of energy, and particularly country-specific clean and sustainable energy leadership, will be a prominent component for achieving manufacturing competitiveness. With increasing demand and limited supplies of conventional energy, market forces are Figure 1: Drivers of global manufacturing competitiveness expected to play a formidable Government investments in role in the development and manufacturing and innovation diffusion of alternative forms of energy and Government investments in the fields of ensure its efficient use. Government science, technology and engineering, policies, which act to increase energy including the establishment and support of efficiencies and accelerate the demand for research institutions; the provision of cost-effective alternative sources of energy, technological support for manufacturers; will provide the springboard, which will and the development of local manufacturing enable a country to gain an edge among clusters create a country-level climate for competing nations. manufacturing innovation. Such government Economic, trade, financial and tax investments foster knowledge creation and systems dissemination, and have a strong positive As mentioned earlier, a country’s economic, influence on the long-term competitiveness trade, financial, and tax systems are key of a country’s manufacturing sector. drivers of its overall level of manufacturing Legal and regulatory system competitiveness. Financial markets provide Legal and regulatory environment, the necessary capital for entrepreneurial regulatory compliance costs, labour laws & and private sector investments in regulations and intellectual property manufacturing. protection & enforcement have a strong Thus, appropriate regulations and influence on competitiveness and growth. policies on corporate taxes, trade, central Absence of a highly transparent and wellbanking and overall financial systems foster functioning legal framework can put the necessary business climate for a investments at risk. Labour laws, which country’s industrial sectors to thrive. In protect the interests of both employees and contrast, burdensome, non-transparent employers and allow flexibility in the and inappropriate regulations and tax deployment of labour, have a positive policies or an unstable central banking and financial system can stifle the Rank Drives Driver score manufacturing sector and impact 10=High 1=Low national competitiveness. 1 Talent-driven innovation 9.22 Quality of physical infrastructure 2 Cost of labour and materials 7.67 The productivity of an industry in 3 Energy cost and policies 7.31 any country is directly related to the 4 Economic, trade, financial and tax 7.26 quality of its physical infrastructure systems for commerce. Physical infrastructure 5 Quality of physical infrastructure 7.15 includes roads, ports, electricity 6 Government investments in 6.62 grids and telecommunication manufacturing and innovation networks. A well-developed 7 Legal and regulatory system 6.48 physical infrastructure is central to 8 Supplier network 5.91 integrating the local market as well 9 Local business dynamics 4.01 as cost-effectively connecting it to 10 Quality and availability of healthcare 1.81 international markets, thereby Source: Deloitte and US Council on Competitiveness -2010 Global Manufacturing enhancing the competitiveness of Competitiveness Index; ©Deloitte Touche Tohmatsu, 2010. Table 1: The drivers of global manufacturing competitiveness are described the entire manufacturing value above in terms of their relative importance to a nation’s progress. chain.

influence on the productivity and efficiency of operations. Supplier network A highly qualified local supplier base supports manufacturing eco-system by contributing significantly to the value-addition of the sector and improving a nation’s manufacturing competitiveness. Manufacturing enterprises have steadily moved away from the vertically integrated business models of the early 20th century. Today, companies compete on the competitiveness of their overall supply chains. They rely on complex supplier networks not only for parts and materials, but also for sharing knowledge and innovation processes. Increasingly, suppliers are becoming vital assets for the manufacturing enterprise, which, in turn, can promote processes that enhance and expand collaboration and teamwork between highly skilled suppliers and themselves. For instance, as more information content is offered in products and as part of associated services, software developers are often deeply embedded in the supply network. When executed successfully, the competitive capabilities of this type of network is formidable, as it underpins the focal manufacturers’ ability to adapt and navigate through uncharted competitive waters. Local business dynamics The size of the local market impacts productivity, as large markets allow manufacturers to exploit economies of scale as well as develop customised products and services. Research shows that market size – population regardless of per capita income – is a relevant driver of multinational firms’ location and investment choices. Competition from local companies as well as foreign multinationals also pushes companies to proactively seek efficiency and productivity as well as innovation. Those that make the grade are not only survivors, but also raise the bar for the entry of future competitors. Quality and availability of healthcare Availability of affordable and quality healthcare is essential for the workforce to be efficient and productive. In the developed world, where the median age of the population is nearing 40, healthcare assumes further significance. Companies are finding that losses due to absenteeism and unfit

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GLOBAL MANUFACTURING COMPETITIVENESS

United States and Canada Drivers Talent-driven innovation Cost of labour and materials Economic, trade, financial and tax systems Energy cost and policies Legal and regulatory system Quality of physical infrastructure Government’s investments in manufacturing and innovation Supplier network Local business dynamics Quality and availability of healthcare Europe Drivers Talent-driven innovation Energy cost and policies Quality of physical infrastructure Cost of labour and materials Legal and regulatory system Economic, trade, financial and tax systems Supplier network Government’s investments for manufacturing and innovation Local business dynamics Quality and availability of healthcare

Mexico and South America Rank Drivers 1 Quality of physical infrastructure 2 Talent-driven innovation 3 Energy cost and policies 4 Economic, trade, financial and tax systems 5 Cost of labour and materials 6 Legal and regulatory system 7 Government’s investments in manufacturing and innovation 8 Quality and availability of healthcare 9 Supplier network 10 Local business dynamics Asia Rank Drivers 1 Talent-driven innovation 2 Government’s investments in manufacturing and innovation 3 Cost of labour and materials 4 Economic, trade, financial and tax systems 5 Energy cost and policies 6 Quality of physical infrastructure 7 Legal and regulatory system 8 Supplier network 9 10

Local business dynamics Quality and availability of healthcare

Rank 1 2 3 4 5 6 7 8 9 10 Rank 1 2 3 4 5 6 7 8 9 10

Source: Deloitte and US Council on Competitiveness - 2010 Global Manufacturing Competitiveness Index; ©Deloitte Touche Tohmatsu, 2010.

Table 2: Regional comparison - Drivers of manufacturing competitiveness

workforce also create a drag on the competitiveness of the manufacturing sector and the overall economy.

REGIONAL PERSPECTIVES There are regional variations in the importance of the competitive drivers that can provide useful insights to policy-makers. While the overall top three drivers remain relatively stable across all regions, there is some juxtaposing in their relative importance. Manufacturing executives within each region localised their views of the top five drivers of manufacturing competitiveness based on the country where they are located. Talent-driven innovation remains the top driver of manufacturing competitiveness across global regions. The exception is Mexico and South America, where executives rate the quality of physical infrastructure as the most important, followed by talentdriven innovation. For European executives, this driver takes third place. Cost-related drivers also take different positions across global regions. Labour and material costs were ranked second by the US and Canadian executives. However, this driver was rated lower by their counterparts from Asia, Europe and Mexico & South

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America, where it fell to third, fourth, and fifth, respectively. Labour cost advantages in developing countries are projected to enable them to continue whittling away at the market strongholds of their industrialised counterparts. Further, the costs of materials have been rapidly escalating because in part, they are fuelled by speculative market prices driven largely by China’s unabated hunger for commodities and this is now making its way through the supply chain. These factors are plausible causes underlying the rising cost pressures the US and Canadian manufacturers are experiencing, especially from the capital markets. Energy costs and policies were viewed as the second most important driver by the European executives, as opposed to third by those from Mexico and South America, fourth from the US & Canada and fifth from Asia. The European Union (EU) faces serious challenges concerning security of supply, import dependence and the competitiveness and effective implementation of the internal energy market as well as those related to sustainability and greenhouse gas emissions. Overall, the EU currently has an energy dependency (total net energy imports as a percentage of gross energy consumption)

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of 53.8 per cent. Minimising the EU’s vulnerability concerning imports, shortfalls in supply, possible energy crises and uncertainty with respect to future supply is a priority for policy-makers as well. The member states, dependent on a single gas supplier, are more vulnerable to energy uncertainty. Clearly, manufacturers in Europe see availability of cost-effective energy and related policies as key to a country’s manufacturing competitiveness. The importance of energy supply is also expected to grow in Asia to fuel the region’s economic growth. However, right now these executives consider energy cost and policies a relatively less important driver. Asian executives do see government investments in manufacturing and innovation as critical – ranking it the second most important driver for manufacturing competitiveness. This view is borne out by China’s direct foreign investment in global resources – steel, oil and minerals – as inputs to its manufacturing sector. China’s foreign investment has increased from $9.11 billion in 2005 to $63.87 billion in 2009, with the majority in energy, metals and chemicals as well as transportation and communications. China undertakes many initiatives to support manufacturing, for example, recalling scientists trained in the developed world. In the Republic of Korea, significant government support has been provided to establish industrial clusters and special economic zones. Notably, such government investment does not appear as a top-five driver for any other regional group, perhaps because of the lesser role governments (versus private enterprises) play in manufacturing competitiveness in these regions. Economic, trade, financial and tax systems versus legal and regulatory systems are two other drivers prioritised differently by executives from different regions. These systems emerged as the third most important driver supporting manufacturing competitiveness as indicated by executives from the US and Canada, whereas those from Asia, Mexico and South America, ranked it fourth. While these systems have typically been viewed as a burden to competition in developed countries, the regulatory systems of the emerging markets have been perceived as ‘anything goes’. The article is an excerpt from the white paper, ‘Global Manufacturing Competitiveness Index 2010’ by Deloitte Touche Tohmatsu

GLOBAL MANUFACTURING COMPETITIVENESS

RISE OF THE

NEW WORLD ORDER The competitive manufacturing landscape is set to witness significant changes in the future. The Asian manufacturing giants – China, India and Korea – will lead the sector, with the superpowers of the late 20th century – the US, Japan and Germany – lagging behind. With the Western and Asian nations vying for manufacturing dominance, the rules of the game seem to be changing. Although most countries seem to be important only within select manufacturing sectors, others have capabilities to be dominant players.

n less than a decade, a new world order for manufacturing competitiveness has emerged along with a tectonic shift in regional manufacturing competence. In particular, the rise in the manufacturing competitiveness of three countries – China, India and the Republic of Korea (Korea) – appears to parallel the rapidly growing Asian market.

THE RISE OF ASIA From the complex web of drivers, the 2010 Global Manufacturing Competitiveness Index (GMCI) reveals some clear competitive trends for policy-makers and manufacturers alike worldwide. Given below are the Asian countries that are riding high on the competitiveness quotient.

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China: China’s ascent to the top of the list is not surprising, given its increasing eminence in the manufacturing sector over the past 10 years, particularly as a regional hub for foreign outsourced production, foreign direct investments and joint ventures. Studies reveal that China possesses strength along most of the top drivers of competitiveness. The availability of large number of highly skilled workers, scientists, researchers and engineers contributes to a high rating for talent-driven innovation. The government’s dedication to investments in science, technology and manufacturing physical infrastructure is aimed at accelerating the technological value-addition of Chinese production and innovation. This advantage coupled with a relatively low cost base that is geographically mutable, gives China a clear leadership position for manufacturing

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competitiveness, now and in the near future. The speed and magnitude of change over the past two decades have strengthened China’s role as a manufacturing superpower. India: Perhaps more surprising is the knowledge that India is now positioned at number two, and is set to gain an even stronger foothold at this position over the next five years. India’s rich pool of talented scientists, researchers and engineers as well as its large, educated English-speaking workforce and democratic regime make it an attractive destination for manufacturers. Since the mid-1990s, India’s software industry has escalated to new heights, and post-economic liberation has also opened the way to unprecedented market opportunities for the Indian manufacturing industry. Moreover, beyond low cost, Indian

GLOBAL MANUFACTURING COMPETITIVENESS

manufacturers have gained proficient in world-class Current competitiveness Competitiveness in 5 years experience in quality manufacturing practices, Index score Index score improvement and Japanese especially as they took a global Rank Country Rank Country 10 = High 10 = High principles of quality management, leadership position in quality and 1 = Low 1 = Low with the largest number of business process management. Deming Award winners outside Today, the US ranks fourth 1 China 10.00 1 China 10.00 Japan. The country is also rapidly overall on the GMCI. Despite 2 India 8.15 2 India 9.01 expanding its capabilities in this position, the US can still 3 Rep. Korea 6.79 3 Rep. Korea 6.53 engineering, design & boast of high labour productivity 4 USA 5.84 4 Brazil 6.32 development and embedded and remains the largest 5 Brazil 5.41 5 USA 5.38 software development, which manufacturing economy, with 20 6 Japan 5.11 6 Mexico 4.84 form an integral part of many per cent of the world’s 7 Mexico 4.84 7 Japan 4.74 modern-day manufactured manufactured outputs, followed 8 Germany 4.80 8 Germany 4.53 products. The importance of by China with 12 per cent. 9 Singapore 4.69 9 Poland 4.52 India for manufacturing players Estimates suggest that technology worldwide underscores two advancement has accounted for 10 Poland 4.49 10 Thailand 4.35 important points. First, strength about 85 per cent of the US 11 C. Republic 4.38 11 Singapore 4.30 in research & development growth in its per capita income. 12 Thailand 4.17 12 C. Republic 3.95 (R&D) – paired with engineering, However, this study provides 13 Canada 4.11 13 Canada 3.71 software and technology some empirical evidence that 14 Switzerland 3.07 14 Russia 3.47 integration abilities – are viewed the competitive dynamics are 15 Australia 3.07 15 Australia 3.40 by global executives as a vital moving downwards for US 16 Netherlands 2.90 16 Spain 2.63 element of the talent-driven and manufacturing, as the US ranking 17 UK 2.82 17 Netherlands 2.63 innovative manufacturing declines to the fifth position in 18 Ireland 2.78 18 Switzerland 2.62 enterprise of the 21st century. five years. This is consistent with 19 Spain 2.67 19 South Africa 2.52 Second, India is increasingly a Milken Institute report that 20 Russia 2.58 20 UK 2.51 being viewed as a place where states, “There is no denying the one can design, develop and fact that the dominance of US 21 Italy 2.42 21 Ireland 2.43 manufacture innovative products manufacturing has been steadily 22 South Africa 2.28 22 Italy 2.37 for sale in local as well as in global eroding.” 23 France 1.70 23 France 1.92 markets. These factors explain, The competition in the US 24 Belgium 1.18 24 Argentina 1.53 in part, India’s rise from a lowmanufacturing sector has 25 Argentina 1.03 25 Saudi Arabia 1.32 cost, ‘back office’ location to a undergone dramatic change. Source: Deloitte and US Council on Competitiveness -2010 Global Manufacturing Competitiveness country well-positioned to be an Globalisation and technological Index; ©Deloitte Touche Tohmatsu, 2010. active participant in the entire progress, especially in advanced Table 1: The collective wisdom of manufacturing executives globally underscores the signiﬁcance of Asia as being the most competitive location for manufacturing in the years to come value chain. Moreover, a large communications, have put number of executives have now American workers in an begun to view the country as an integral manufacturing industries have now garnered unprecedented level of direct competition part of their global manufacturing enterprise recognition in the global arena, with Korea with its lower-wage counterparts as well as and location strategy. emerging as the world’s largest shipbuilding with rising leading-edge talent pools available Korea: Korea currently stands at the third nation and ranking first in terms of worldwide. Much of this projected decline position and will continue to maintain this in semiconductors and displays. Moreover, is attributed to the hollowing out of the next five years, strengthening Asia’s Korean automobile manufacturers are now manufacturing by the outsourcing of not dominance in the new world order of the a significant force around the world as are only millions of US manufacturing jobs, but manufacturing industry. Korea’s position is its appliance makers. also, increasingly, the export of R&D and based on its economic growth over the past customer support to foreign partners and CHANGING DYNAMICS FOR decade and its steadily gaining strength that subsidiaries. Many manufacturing skills – SUPERPOWERS is built largely on the back of its strong such as welding, software development for The dominant manufacturing superpowers manufacturing sector. With many of its numerically controlled machines and quality of the late 20th century – the US, Japan and largest companies vertically integrated, management – have a high degree of Germany – are now lagging on the GMCI Korea has ceaselessly heightened the valueaccumulated tacit knowledge and, if lost, is as compared to the three Asian juggernauts. addition of its production & technological difficult to recover. Moreover, the added This may indicate the changing rules of the innovation through a persistent focus on complexity costs of long supply chains are game, thereby limiting the influence of economic development, targeting industrial not well understood. The projected decline traditional Western theories and sector growth and exports. can also be seen as driven, in part, by a conventional wisdom. Korea’s industrial policy supports a broad perception that a services sector can sustain The US: The late 1980s and early 1990s base of manufacturing infrastructure prosperity without the vital support of a was a period of manufacturing renaissance development, including industrial parks, strong manufacturing sector and from a lack in the US, as manufacturers became ports and transportation systems. Key of a cohesive national policy on

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GLOBAL MANUFACTURING COMPETITIVENESS

QUICK TAKE Since the mid-1990s, India’s software industry has escalated to new heights, and posteconomic liberation has also opened the way to unprecedented market opportunities for the Indian manufacturing industry. Manufacturing accounts for one-quarter of Germany’s gross domestic product (GDP), 30 per cent of its jobs, and the label ‘Made in Germany’ continues to be a symbol of superior quality. Germany’s reliance on exports to the European Union (EU) has also shielded it somewhat from the fluctuating Euro. manufacturing competitiveness. Japan: In the 1980s, Japan was heralded by many as the epicentre of manufacturing best practices. The tide turned in the 1990s, the ‘lost decade’ caused by an overall economic downturn. The manufacturing leadership once enjoyed by Japan is now profoundly altered, with China being viewed as the new Asian anchor. A recent study on Japanese manufacturing competitiveness strategy reports that Japan is facing formidable competitive pressures due to a declining workforce, an aging population and the ‘loss of a manufacturing culture’. In addition, Japan faces higher manufacturing costs as well as a relative scarcity of natural resources, which means it must import raw materials along complex supply chains. While it is rapidly replacing line workers on the shop floor with complex robotics – an area of strategic manufacturing strength – it is scaling up its production workers with higher-cost scientists and engineers. Today, about one-third of Japan’s employees are engineers. The study also reported that Japan is rapidly replacing workers. As a result, many Japanese manufacturers are emphasising on ‘designbased production’, which implies that physical production and design should be combined. The emphasis on robotics also signals the need for the co-evolution of the mechanical, electrical and software aspects of its product and process development. Yet, Japan’s relative competitiveness in software development is reportedly weak. An academic study concluded that in terms of software, “There is an overwhelming import surplus, with exports less than 10 per cent of the value of the imports.” Further, like their US counterparts, many Japanese manufacturers continue to outsource and/or offshore their more routine manufacturing operations, particularly to other low-cost Asian countries, which may reduce their country leverage and expertise. Further, in the next

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five years, Japan is expected to drop from sixth to seventh place on the GMCI. Germany: The global executives rank Germany eighth on the index – which may seem confounding as German manufacturing is often touted to be among the most competitive ones worldwide. German manufacturers have steadfastly pushed the envelope in ‘mechatronics’ – the science of merging information technology, electronics and conventional mechanics. Manufacturing accounts for one-quarter of Germany’s gross domestic product (GDP), 30 per cent of its jobs, and the label ‘Made in Germany’ continues to be a symbol of superior quality. Germany’s reliance on exports to the European Union (EU) has also shielded it somewhat from the fluctuating Euro. Even with the economic downturn and the declining overall European demand, Germany is still benefiting immensely from the booms in India and Brazil. Particularly in China, as the country moves away from consumer products towards making more sophisticated, high-technology products, the demand for Germany’s specialised manufacturing systems – precision machine tools, highly engineered goods and complementary technical support services – has shot up to keep pace with these developments. However, these benefits may only be for a short term. Although Germany’s rank remains the same in five years, its actual index value declines. China is rapidly moving up the technology ladder, making a significant headway in renewable energy, aircraft and automobiles, catching up with Germany in some sectors like wind power generators. Other reasons cited as eroding Germany’s competitiveness are its bureaucracy, sluggish pace of start-ups and relatively high labour costs. As per reports, Germany’s high labour costs are likely to be construed as reducing its competitiveness. Employee wages in western Germany are nearly double that of US counterparts, which are, in turn, higher than those paid to

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Japanese workers. Manufacturers are more likely to be drawn to eastern Germany where hourly employee labour costs are substantially less. Thus, while the US, Japan and Germany remain three of the most formidable manufacturing locations in the world, their future GMCI, based on the input from executives surveyed, shows their competitiveness eroding. The index indicates that the competition is already heating up, and in the next five years the staying power of these manufacturing giants of the 20th century will be challenged even more.

MARKETS TO WATCH A review of the remaining countries on the index indicates that several newcomer economies are soaring in importance as manufacturing hubs. In particular, Brazil, Mexico, Poland and Thailand are expected to improve their manufacturing competitiveness in the next five years, when each of these countries will become a part of the 10 most competitive locations, most likely due to either their natural resources or attributes of their workforce. Brazil has surpassed the US into the fourth position and is nearing to overtake Korea. Mexico, despite a constant index value, moves into sixth position, replacing Japan. Further, both Poland and Thailand are moving up, reaching the top 10 in the ninth and tenth positions, respectively. Also experiencing significant progress on the index are the economies of Eastern Europe and of Russia, which are showing strong competitive potential. Brazil: Almost as impressive as the ascendance of Asia, is the rise of Brazil and Mexico in the Western hemisphere. Particularly noteworthy is Brazil’s impressive advance on the GMCI in five years, based on a significant improvement in its own index value and a decline in the index value of the US. Brazil’s manufacturing sector has historically focussed on commodities and the export of low-technology products, with the exception of aerospace. It has also pursued an industrialisation policy centred on replacing imported manufactured products with Brazilian-made ones, yielding a highly diversified manufacturing sector. Industrialisation has evolved with infusion of domestic capital investment by the government in industries such as steel, petrochemicals and aircraft; and by foreign capital in automobiles, chemicals and electrical goods manufacturing. As a result,

GLOBAL MANUFACTURING COMPETITIVENESS

today, Brazil is one of the world’s major any country on the list), the Netherlands, for a range of manufacturing activities steel producers and car manufacturers. the United Kingdom, Italy and Belgium. including automotive and electronics, due Moreover, Brazil can draw on its significant Each of these countries experienced to its cost competitiveness with western resource wealth and further develop its deterioration in their current GMCI rank Europe. Its large qualified talent pool, a technological edge in agriculture and and future index value. Only Spain moved sizable domestic market and close proximity alternative energies in order to capture the up from rank 19 to 16, albeit with a lower to customers across Europe are added more profitable stages of the value chain. index value, surpassing its falling western advantages. Brazil is also one of the few countries with a European counterparts in the relative Notably, the most significant move on sufficiently large natural resource base and a position. Further, France, while remaining at the entire GMCI belongs to Russia, which relatively sophisticated research the 23rd place, is the only western European jumps from 20 to 14. This may reflect nation that actually appears to improve its infrastructure in promising sectors such as Russia’s current initiative to create an index value and relative strength over the bio-fuels. These advances place it in a innovative economy supported by an next five years. unique position, especially for its growth in environment where talent and business an ecologically sustainable way. acumen can be brought together. THE COMPETITIVE In addition, Brazil’s hosting of the FIFA Government emphasis on the education CHALLENGE World Cup in 2014 and the Olympics in and development of the workforce will play The GMCI rankings ascribed by senior 2016 is expected to improve infrastructure a critical role in this effort. It is also likely that manufacturing executives in this study and bring in foreign investments, which are executives in the study are eyeing the indicate that barring any significant macrolikely to have a positive influence on the strategic moves by the EU in recent years level shocks, such as war, economic country’s manufacturing sector. to bolster relations with Russia. Most of the collapse, natural catastrophe, major shifts Mexico: The signing of the North American foreign direct investments in Russia come in consumer dynamics or major Free Trade Agreement in 1994 helped set from the EU. Moreover, as Russia’s thirdgovernment interventions, the competitive the stage for the current manufacturing largest trading partner, the EU aims to landscape for manufacturing will be strength of Mexico. Mexican manufacturing improve cooperation in several areas. significantly altered in the next five years. plants were initially located along Mexico’s Interestingly, Russia’s momentum within Of the 10 most competitive manufacturing northern border, and today, most of the the GMCI appears to be largely driven by locations, five will be in Asia, two in Europe manufacturing plants are located south of the perspectives of executives from China. and the remaining three in the Western the US. Throughout Mexico, however, the China has been seeking opportunistic hemisphere, with two in North America. manufacturing industry has become a key relationships with Russia to garner strategic Mexico moves at the sixth position, and engine for growth in the overall economy. mineral and oil resources, military weapons the US falls to the fifth, replaced by Brazil Mexico now ranks 11th worldwide in and hardware and to increase cross-border automotive production with globally – sandwiching US manufacturing between business and tourism. The influence of recognised quality. Manufacturing of its western hemisphere counterparts. China on Russia’s rising index rank is further electronic components, building and Western Europe sees a near across-thecorroborated by China and Russia’s current construction materials, aerospace products board decline in manufacturing plans to expand co-operation on the deep and other areas of labour-intensive competitiveness, while Eastern Europe processing of raw materials as well as within manufacturing constitute the other large picks up steam. The Asian manufacturing the aircraft and hi-tech sectors. industries in the Mexican economy. Mexico juggernauts – China, India and Korea – LOSING GROUND: WESTERN has also begun to develop a broader and remain at the top of the manufacturing EUROPE more technologically sophisticated portfolio pyramid. Overall, the story for Western Europe is a The regional implications of the GMCI of products that enable it to leverage sobering one. While Germany maintains its could be significant, as North America, significant foreign direct investment and an grasp on the index’s eighth position, western South America, western and eastern abundant, young and eager workforce. Europe witnesses decline for Switzerland Europe and Asia all challenge each another Manufacturers in Mexico still enjoy lower (the most significant downward change for for dominance in manufacturing – a vital labour rates, while many of its plants now source of jobs and country manufacture higher-quality Moving up Rank change Sliding down Rank change prosperity. Many of these rising products supported by better Brazil 5th to 4th USA 4th to 5th countries appear destined to be technology, and specialisation in Mexico 7th to 6th Japan 6th to 7th important only within select key areas. Proximity to the US manufacturing sectors, while has boosted Mexico’s Poland 10th to 9th Singapore 9th to 11th others possess the breadth and manufacturing potential and has Thailand 12th to 10th Czech Republic 11th to 12th depth of resources and helped position it firmly in the Spain 19th to 16th Netherlands 16th to 17th capabilities to be dominant top rankings of the most Russia 20th to 14th Switzerland 14th to 18th players across the board. competitive manufacturing South Africa 22nd to 19th UK 17th to 20th locations. Argentina 25th to 24th Ireland 18th to 21st The article is an excerpt from the Eastern Europe and Russia: Saudi Arabia 26th to 25th Italy 21st to 22nd white paper, ‘Global Manufacturing Eastern Europe has a few Belgium 24th to 26th Competitiveness Index 2010’ by significant bright spots. Poland Table 2: Expected change in manufacturing competitiveness in 5 years Deloitte Touche Tohmatsu remains an attractive location

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A HIDDEN GREEN GIANT READY TO TAKE THE LEAP With rising levels of awareness on eco-friendly practices, the manufacturing sector in India is now becoming proactive to imbibe remanufacturing, also termed as the ‘hidden green giant’, in their business activity. Aiming at profitability and sustainability, remanufacturing provides the right solution for both manufacturers and customers to limit waste generation and increase the life of a product.

SUMEDHA MAHOREY

emanufacturing or ‘reman’ is an upcoming industrial operation in which an existing product is recovered from commercial use and utilised as input for the remanufacturing of the same product. Today, with new concepts emerging globally at much faster pace, coupled with higher immediate levels of awareness in all-important markets,

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remanufacturing holds a huge market potential and sustainable outlook. It has resulted in continuous two-digit growth rates since its inception towards the end of the nineties worldwide. In India, remanufacturing is now being accepted by manufacturing industries, which consider it as a new profitable business model.

WHAT IS REMANUFACTURING? Remanufacturing is described as the process

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of disassembly of products in which parts are cleaned, repaired or replaced and reassembled to sound working condition. According to the Remanufacturing Institute, Chantilly, USA, a product is considered as remanufactured only if: Its primary components come from a used product The used product is dismantled to the extent necessary to determine the condition of its components

REMANUFACTURING

The used product’s components are thoroughly cleaned and made free from rust and corrosion All missing, defective, broken or substantially worn parts are either restored to sound, functionally good condition, or they are replaced with new, remanufactured, or sound functionally good used parts To put the product in sound working condition, operations such as machining, rewinding, refinishing or other processes are performed as necessary The product is reassembled and manufactured in such a way that it operates like a similar new product. Remanufacturing differs from recycling and makes a much greater economic contribution per unit of product as compared to recycling. The basic aim of reman is to recapture the value added, which is by far the largest element of cost. In any product, the cost of the basic raw material is much less than 5 per cent of the cost of a finished product. The rest of the cost factor is value added, which includes the cost of labour, energy and manufacturing operations that are added to the basic cost of raw materials in the manufacturing of a product. Pradeep Sen, National Sales Manager Services, Timken India, explains, “The remanufacturing activity that we do in India is basically a back-end function that supports the sales of new bearings, as well as the onsite service business that we undertake to maintain bearing shop of any process industry. The activity makes sure that the customer actually capitalises on the product and gets the best value out of it. So, when a bearing under service is identified for repair, we take it back to our service centre, repair it and give it back to the customer at a very nominal price. Thereby, the customer does not have to invest in the new bearing altogether, and he can get more value out of the product that he has purchased.” He further adds, “When the time comes wherein no further repair job can be done or when the repair work exceeds 50 per cent the cost of the new bearing, we recommend the customer to go for a new bearing.” In a country like India, which is the second most populated country in the world with over 50 MT e-wastes generated every year, and a huge number of automotive components and heavy equipment disposed off as waste, the

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Overall Global Savings Energy: The energy savings through remanufacturing worldwide amounts to 120,000,000,000,000 BTUs (British Thermal Units) a year. This amount of energy equals: 16,000,000 barrels of crude oil, which equals a fleet of 350 tankers or the lifetime fuel consumption of 75,000 car owners Electricity generated by eight average size nuclear power plants Energy needed for industrial and commercial activities of 1.8 million employees in total. Materials: The savings of materials by remanufacturing worldwide amounts to 14,000,000 tonne a year. This quantity of raw materials is eqivalent to: A train with 2,30,000 full cars, occupying a track of 1,650 miles in length. Source: World Trade Organization

remanufacturing industry has a vast potential. According to leading Indian manufacturers, the players in India have made a slow start in this arena, but have started realising its potential for the future.

ENVIRONMENTAL BENEFITS The remanufacturing activity results in enormous energy and material savings, coupled with the minimisation of solid waste. As compared to the production of new equipment, around 85-95 per cent less energy and materials per product is required in the remanufacturing process. According to studies conducted at the Fraunhofer Institute, Stuttgart, Germany, worldwide the energy savings in a year through remanufacturing equals the electricity generated by 5 nuclear power plants or 10,744,000 barrels of crude oil, which corresponds to a fleet of 233 oil tankers. The Fraunhofer Institute also determined that raw materials saved by remanufacturing worldwide in a year would

Remanufacturing would be attractive for market players as the capital/ infrastructure costs are relatively low and there is a distinct wage advantage. However, it is unlikely to be done on a large scale and may mostly be carried out by the SME segment. K KUMAR, Leader-Manufacturing, Deloitte in India

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fill 1,55,000 railroad cars forming a train 1,100 miles long. Also, products that are remanufactured are kept out of the waste stream longer, landfill space is preserved and air pollution is reduced from products that would have had to be resmelted or otherwise reprocessed. A product can always be recycled. Extending product life through remanufacturing is the key to leveraging the earth’s natural resources and also helps in curbing environmental problems before they occur by reducing potentially harmful waste. The consumers and businesses can now choose between purchasing a less expensive, remanufactured product or a similar, typically more expensive product manufactured from virgin materials. The remanufactured product may be technologically identical to the competing product made from virgin materials. Alternatively, the remanufactured product may fill a market niche for highquality, fully functional and more affordable product applications. Thus, the two processes – remanufacturing and new product development – can complement each other and reduce the negative impact on the environment. In addition, energy savings can also be achieved in the production and the product operation stages as the energy needed to manufacture one new product is usually 10 times greater than that needed to remanufacture an old product. Apart from this, remanufacturing helps in reducing waste over the product life-cycle, bringing down the emission of nearly 28 million tonne of carbon dioxide every year, besides adding several life-cycles to a product beyond its first life.

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OTHER BENEFITS

effectively convince new customers to economical and ecological contributions of Remanufacturing by original equipment use reman the remanufacturing industry makes it Mass production mentality of the OE manufacturers (OEMs) and independent difficult to garner legal or regulatory support divisions that does not fit well with the remanufacturers results in substantial to counter these threats. This also impacts low volume reman requirements for benefits for both. Producers of new goods the long-term profitability and growth for replacement parts benefit by shifting resources to new, more aftermarket remanufacturing products. If Remanufacturing is not addressed as a value-added product lines, while only the automotive industry is taken into ‘product value stream’ approach, but as remanufacturers meet after-sales services consideration, remanufacturing companies a service need after OE production demand on other product lines. K Kumar, would increasingly face the challenge of Leader-Manufacturing, Deloitte understanding and managing in India, avers, “Remanufacturing The remanufacturing activity results in enormous energy complex mechatronic systems helps in lowering the capital cost such as electronically-controlled and material savings, coupled with the minimisation of automatic for the user of the equipment transmissions, solid waste. while avoiding the issue of electrically-assisted power disposal/retirement of the steering, electrically-driven Lack of a well-defined remanufacturing equipment for some more time. Further, water pumps, integrated starters, alternator business case analysis model to assist there is a manufacturer’s warranty that the devices, etc. This will require a business managers to make timely user enjoys. It also helps manufacturers multidisciplinary approach, which requires decisions. Consequently, the programme who are looking to enter low price-point access to information and specification data manager frequently makes delayed markets where the customer expectations from automotive OEMs. Kumar says, “In a decisions based on remanufacturing are not high.” number of cases, the original design is volume Traditional manufacturers improve on required at the time of remanufacturing. Lack of proper metrics to measure the existing products while remanufacturers Such availability may be a problem. Also the impact of missed reman business identify design flaws in the cores. quality and/or efficiency of remanufacturing opportunities, including, ‘design for Remanufacturing, thus, lessens the need to may be suspected where version controls remanufacturing’ business opportunities. maintain large inventories of outdated are not managed.” Threats to the industry also come in the replacement parts. When a product line is However, Sen has a different view on form of new products that have become discontinued, remanufacturing can fill the this. He elaborates, “Normally, we do not inherently more durable and reliable, void. In many industries, remanufacturing is face any design challenges as Timken in the requiring fewer rebuilds during a product’s an essential part of the overall business US has been practising remanufacturing for lifetime, and from new inexpensive model that enables provision of a range of almost 60 years in North America, and products, largely imports, that make warranted products at competitive prices. rebuilding of bearing housings and rolls remanufacture uneconomical. Further, Products for which remanufacturing has since the last 40 years. During the course of threats come from anti-competitive tactics been initiated are motor vehicle parts, this period, we have generated enormous on the part of OEMs, some of whom have robots, aircraft parts, compressors, data amount of database on not only Timken sought to use patent and copyright laws to communication equipment, electrical products, but also on competitors’ products. stop remanufacture of their products. apparatus, etc. So for any make or type of bearings, the Lack of public sensitivity to the internal geometry specification or any other ISSUES AFFECTING remanufacturing dimensional specification REMANUFACTURING would in most likelihood be already known There are numerous legal, regulatory, and to us and the database would be existing in other issues that affect remanufacturers on North America. Even if, we have to The scope for remanufacturing as a a daily basis. Some of the issues prominently remanufacture non-Timken products, we affecting remanufacturers are core valuation, can do it easily by acquiring the geometry business model is bright. There will be intellectual property and anti-trust data from our North American service a day when industries will primarily matters, design for remanufacturing and centres.” depend on rebuilt products and will Also, environmental initiatives from big government’s economic incentives. hardly invest in new products.Thus, corporations are mostly specialised activities According to a research paper on rather than mainstream business strategies. ‘Remanufacturing for the Automotive remanufacturing business would Such ad hoc solutions in the absence of a Aftermarket-Strategic Factors’, other eventually give a complete new strategic framework, lead to inappropriate problems that are impacting this industry dimension to the industry and evolve and inadequate support for reman projects. are: as a business model with a huge Misalignment among original equipment market space. RECENT TRENDS (OE) divisions on product design needs Nowadays, most customers are becoming for remanufacturing, which results in maintenance-savvy while trying to reduce wasted efforts during the process or may PRADEEP SEN, their maintenance cost. Sen points out, “At lead to a failed business opportunity National Sales Manager - Services, Lack of proper technical, environmental, present, customers are moving towards Timken India and quality data within OE divisions to predictive maintenance, refurbishing and

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remanufacturing, even offloading bearing maintenance to experts like us. These bearings are generally high-value products, starting from as low as $2,500 to as high as $2,00,000. If refurbishment can be done at a nominal price, then the customer first acknowledges it. We have also been doing a lot of remanufacturing for even competitive products and are attracting increasing number of customers for this kind of service.” Moreover, with remanufacturing showing robust potential as a completely new business model for manufacturers, more products can be targeted by this upcoming industry. While elaborating on the products for which this can be initiated, Kumar says, “Theoretically, it can be a number of products. It is likely to be capital equipment where the wear and tear suffered by different components is of varying degrees. This would mean that one can use the residual life of the larger structural member or component by replacing the more worn-out component.”

POLICY INITIATIVES Primarily, the government should encourage the reduction in maintenance cost by public

sector units. Sen avers, “The government should promote repairing and rebuilding activity in its units, so that when it comes to branded manufacturers like us, they should entrust us by trying out the repair and rebuild service, since we are already selling new bearings in their plants. Normally, customers have a perceptive apprehension that repaired and rebuilt products may not perform well. Nowadays, branded companies like us are the actual manufacturers, are coming up with appropriate machineries to perform this kind of an activity. Hence, the public sector undertaking should trust us, so that they can save on their actual maintenance cost.” With regard to special incentives for the remanufacturing industry, Sen elaborates, “The government needs to address issues pertaining to the excise and service tax rules. These can be made favourable, so that more number of customers can come forward for the maintenance activities.”

OUTLOOK With remanufacturing grabbing the attention of the Indian manufacturing industry for its multiple benefits and profitable business potential, the industry would see rapid developments in the near future. Kumar

highlights, “Remanufacturing would be attractive for market players as the capital/ infrastructure costs are relatively low and there is a distinct wage advantage. However, it is unlikely to be done on a large scale and may mostly be carried out by the SME segment. Further, if there are technologies/ drawings that the original manufacturer needs to share with the remanufacturer, it is likely to be related to dated technology. Therefore, remanufacturing is likely to be a niche activity, looking to move to low-cost locations all the time. There are likely to be high-end remanufacturing areas that are technology/know-how heavy, which would stay with the OEMs.” Elaborating further on the future of this industry, Sen asserts, “The scope for remanufacturing as a business model is bright. There will be a day when industries will primarily depend on rebuilt products and will hardly invest in new products.They will rebuild and replace components as and when the need arises to keep their equipment in good shape. Thus, remanufacturing business would eventually give a complete new dimension to the industry and evolve as a business model with a huge market space.”

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FIBRE OPTIC FILMS TO ENABLE TWO-DIMENSIONAL DISTRIBUTION OF LIGHT Though light-emitting diodes are used in a number of products such as televisions, cellphones, laptops, etc, their manufacturing still seems to be a complex and expensive affair. Also, as these are point light sources, the even distribution of light over large surfaces without much energy loss is difficult. To overcome these drawbacks, a new technology is being developed, wherein fibre optic films will be used, thereby, distributing light two-dimensionally. SUDHIR MUDDANA oday, light-emitting diodes (LEDs) are being used on a wide scale as background lighting for displays. In the case of televisions, screens are becoming increasingly flatter; some are almost as thin as a sheet of paper. Their size takes impressive dimensions, much to the delight of home cinema fans. In the case of cellphones and laptops, screens have ever brighter and more brilliant displays. This is due to the miniature lightemitting diodes that beam background lighting into a multitude of devices. Though it gives the displays a new dimension, LED technology does have a disadvantage. It is a point light source. But displays are twodimensional. So how does one distribute the light from an LED evenly on as large a surface as possible, that too, without massive energy loss. Moreover, the manufacturing of LED optics is complex and expensive. To overcome these issues, a new technology is being developed, wherein large-scale LED components can now be manufactured cost-effectively and also solve the problems pertaining to even distribution of light.

The superﬁcial structures of this sheet are only a few micrometre in size.

cost-effectively and with energy-efficiency during mass reproduction. Ramakrishna averred, “The products are many and include most optical products – all kinds of displays, power-saving illumination systems, imaging systems, and so on.”

transparent and optically conductive plastic panel. About the use of this new technique in India, Ramakrishna explained, “The new production technique appears to be at the testing level even with the developers and does not seem to have yet been introduced in the industry even there. In India, there are some research laboratories that have taken up development of diffractive optics – IRDE Dehradun and IIT Delhi. But I do not think that anybody is working on the development of large-scale diffractive optics in this manner. Introduction of this technique in India will depend on the type of industry – whether they want to take up the challenge of implementing a new technical development or not.”

DEVELOPMENT PROCESS IPT researchers have developed a process chain with which they can populate largescale sheets with the necessary microstructures. “It‘s an ultra-precise process,” said Dr Christian Wenzel, Senior Engineer, IPT. Using pinpoint accuracy, the machine must apply the smallest structures – just a few micrometre in size – on the surface of the film in a periodic sequence. “In order to produce the stamp, we use special diamond tools,” added Wenzel. The stamp that consists of a gossamer-thin nickel sheet is also infinitesimal, i.e., its surface equals at most two by two millimetre. Like

GAUGING THE PERFORMANCE INDEX

To understand if the microstructured master possesses the desired characteristics, it will first have to be tested. If approximately 80 per cent of the surface is completely structured, the properties of the sheet can be analysed. If these properties are not consistent with the optical design settings, then the machine can implement the THE GENESIS necessary corrections during the imprint Fraunhofer Institute for Production process. “We are optimising the component Technology (IPT), in Aachen, will soon be while it‘s still in the machine,” said Wenzel, producing fibre optic films that will ensure explaining the advantages. two-dimensional distribution of Once the plastic surface has light. While elaborating about the desired light control The new fibre optic films will possess superficial capabilities, then the engineers how fibre optic films will help to distribute light two-dimensionally, structures measuring in the single-digit micrometre immerse the master into a nickel Dr SA Ramakrishna, Associate range, while the sheets themselves measure at two bath and galvanise it. The nickel Professor, IIT Kanpur, said, “I shim created in this manner can by one metre in size. believe that it is an array of then go into mass replication. diffractive optical elements that According to Ramakrishna, “The they are probably using that map the more a dot matrix printer, it must then process a conditions in India for most of the above isotropic emission from a LED source to a sheet measuring two by one metre in size, products are not different. The main more planar pixel used for display and guided by the ultra-precision machine. difference is the more extreme weather illumination purposes.” “Within a few days, we completely conditions here. The fibre optic films would The films will possess superficial structured the entire surface. With the have to be far more resistant to corrosion structures measuring in the single-digit previous approach, the process would have as well as be better sealed in India. But then micrometre range, while the sheets taken weeks or even months,” said many things like the compact fluorescent themselves measure at two by one metre Wenzel. light (CFL) for illumination work well in India in size. In addition, they can be produced The preliminary product is the master: a as well as the Western countries.”

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CUTTING EDGE SOLUTIONS

COST-EFFECTIVE START-STOP SYSTEMS FOR ULTRA-COMPACT CARS With rising demands for cost-effective and environment-friendly cars, a start-stop control system has been developed by Continental Automotives recently. The system holds the potential to reduce the overall fuel consumption of vehicles by up to 15 per cent. SUMEDHA MAHOREY ith an aim to pave way for ecofriendly vehicles and also curb fuel consumption, the interior division of Continental Automotives has recently developed a new control unit. This control unit conforms to pollution norms by reducing consumption of fuel by automobiles.

need to ensure fuel efficiency in India, the demand for eco-friendly and cost-effective cars has increased. With the help of the start-stop system, we expect up to 15 per cent reduction in fuel consumption in major cities like Delhi and Mumbai.” The components for start-stop systems for vehicles in the lower price segment come as a response to the efforts being

AUTOMATIC START-STOP SYSTEM The control unit makes it possible for vehicle manufacturers to offer models in the ultra-compact category, with an automatic start-stop system in a short span. When the vehicle is at a standstill, for example, in a traffic jam or at traffic signal, the engine is automatically switched off and then restarted within a few fractions of a second when the driver wants to move on. Torsten Kreiling, Head - Business Unit Body & Security, India, Continental Automotives, points out, “With the implementation of the start-stop control system, drivers will not have to worry about putting off the engine at signals & during traffic jams. The system will automatically stop the engine and save on fuel costs. The major benefit of this system is that the engine restarts in a fraction of a second, making it highly efficient for the Indian conditions. Plus, it works for both gasoline and diesel engines. All automotive segments – small cars, mid segment, higher segment – can benefit from this system. The response from OEMs has been good. Two Indian companies have already initiated the implementation of this system for their respective automotive segments.”

REDUCING FUEL CONSUMPTION Continental expects everyday fuel consumption to be reduced by as much as 15 per cent in major cities as a result of the benefits offered by the automatic start-stop system. Krieling avers, “With people becoming increasingly conscious about the

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of a second when the clutch pedal is pressed. One particular advantage of this system is its short development time. Highlighting the fact, Krieling elaborates, “If an OEM asks us to implement the control system, the development time would depend on the car specification, but we can achieve it in a year’s time.” All relevant functions are combined in a single control unit, so there is no need to modify the engine control unit (ECU) or gearbox ECU. This reduces complexity and makes it possible to start series production sooner.

SERIES PRODUCTION

Continental’s Basic Function Controller is the basis for the start-stop system, especially designed for ultracompact cars.

made in many developing countries to combine mass mobility with the most frugal possible use of natural resources. Moreover, new pollution emission limits are being discussed in many of these countries. For example, India is currently considering whether to launch a special vehicle registration as a means of promoting sales of particularly low-fuel consumption cars from 2011 onwards. The new engine start-stop (ESS) control unit, which groups together all the relevant functions, makes it possible to switch off the engine automatically even in cars that do not have elaborate engine control units or data networks. To do this, all that is needed is the start-stop control unit itself, an intelligent battery sensor (IBS) as well as a signal from the clutch and gearbox to ensure that the engine is only switched off when idling and is restarted in just a few fractions

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The new control unit will enter series production in 2010. Practical experience has shown that start-stop systems can achieve their full savings potential, especially when the driver is informed quickly and clearly about the operating phases that are involved. Despite the fact that the new ESS control units can be adapted to different vehicle models at short notice, and have been designed above all for use in cars in the lower price segments, the driver will not notice any difference between them and comparable systems in higher category models. This is because the levels of comfort, functional reliability and the potential for fuel savings are identical. An automatic start-stop system offers vast savings potential. Various standard and test cycles conducted in Europe, the US, China and India, reveal that an average consumption reduction of up to 10 per cent can be assured through the use of this system. Significantly, greater consumption benefits can be achieved on a daily basis. After all, traffic jams and delays are part and parcel of urban life in megacities such as Delhi, Shanghai or São Paulo. Therefore, the advent of technologies such as startstop systems will go a long way in achieving fuel efficiency and a clean environment.

HUMAN MACHINE INTERFACE

WHERE SOPHISTICATION MEETS SIMPLICITY

The increase in speed and computational power of human machine interfaces (HMIs) has made them more flexible in their widespread applicability. They can be used as multi-tasking devices that can perform quality control, data acquisition, and other tasks while serving as the operator station controlling a process. With HMIs getting smaller, smarter and better, it can be applied to control problems in a reliable and sophisticated manner, besides offering cost-advantages. hirty years ago, operator stations consisted of indicators, push buttons, and often a recorder, all mounted on the door of a large enclosure or on the face of a pedestal enclosure. Inside the box was the programmable logic controller (PLC), and each of the components of the operator station had to be hard-wired together by hand. Each of the terminations and components was a single point of failure just waiting to happen, and the cost of producing each operator station was high. Coming back to the present, all the features and functions of an operator station can now be done with a single device â&#x20AC;&#x201C; the human machine interface (HMI). HMIs are panel-mounted embedded computers that have several functions of a

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programmable controller. But they are designed to emulate the electro-mechanical controls of earlier times, exactly like the PLC was designed to emulate and supplant the electro-mechanical relay of yesteryears. HMIs have an integral touchscreen display, usually an LCD, and can be supplied in different sizes, with a variety of features, display resolutions, and programming capabilities from simple to highly complex.

FROM STANDALONE COMPONENTS TO THE HMI The shift from standalone components to the modern HMIs actually began with the PLC. The PLC was developed to reduce the time taken for automotive plant assembly line turnaround. By replacing hardwired relays with firmware and logic, it became possible to establish set-ups in a

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matter of hours rather than weeks. Unfortunately, it took more time to wire the operator panels than to download the new programme into the PLC and to do the necessary re-wiring to repurpose the PLC for the new set-up. The time taken to build the operator panel depended on the complexity of the panel, which, in turn, depended on the application. A simple conveyor control panel, for example, might include an E-stop, a speed vernier connected to a variable frequency drive (VFD), a readout (LED or analog dial), a Hand-Off-Auto (H-O-A) switch, and a set of contactors to operate the conveyorâ&#x20AC;&#x2122;s motor. Changing to a solidstate HMI panel removes all those components and their associated wiring, and the failure points from each of the terminations of those wires. All that remains

HUMAN MACHINE INTERFACE

is the VFD, the contactors and the HMI panel. Operator panel construction and installation time was reduced as much as 90 per cent in cases where the panel controls were complex.

Today, HMIs are also equipped with standard networking communications, such as Modbus, Fieldbus, and industrial Ethernet versions, so that they have made the simple operator panel into a powerful communications node on the plant LAN.

operator had performed the wrong actions. Better training, use of HMIs and simulation, have many-a-time helped in preventing accidents.

OPEN ARCHITECTURE

IMPROVING SYSTEM RELIABILITY

One of the benefits of the microcomputer revolution is the increasing Removing components and reliance on commercial-offHMIs are getting smaller, faster, smarter, and less their associated wires not only the-shelf (COTS) designs, costly over the last ten years. They can be applied saves construction and which can be repurposed for installation time, but also industrial use. This includes to sophisticated control problems, can do complex maintenance time. Fewer hardware, software and mathematics, handle alarm management algorithms, components resulted in less firmware. Early PLCs, for and produce sophisticated graphics in real-time. maintenance, especially when example, were proprietary the removed electrocomputers with real-time KEEPING IT SIMPLE mechanical components were responsible operating systems. The use of Microsoft The decrease in component items on the for more than half of all maintenance calls to Windows operating system in HMIs and bill of materials for an operator panel operator panels. programmable automation controllers compared with the purchase price of an Removing the majority of individually (PACs) has made it possible to produce appropriate HMI panel provides cost wired components improved the mean software that is portable, because it was benefits. Along with this, the reduction in time between failures (MTBF) of the developed for the open architecture of the labour necessary to programme and wire operator panels and reduced the number PC. Standard open architecture I/O has the HMI compared to that required to build of potential points of failure in the panel. also been adopted, both for networking and wire a conventional operator station Replacement of individual indicator lights, and adding components and functionality to results in cost reduction of up to which were usually incandescent bulbs with the HMI. This has greatly reduced the cost, 50 per cent or more. MTBFs in the hundreds of hours, with a improved the availability, and also the The typical 10â&#x20AC;? HMI panel is in the range backlit HMI â&#x20AC;&#x201C; whose backlight was rated robustness of the industrial HMI. of $1,200-2,500, depending on features around 35,000 hours â&#x20AC;&#x201C; is an example of the SOFTWARE DEVELOPMENT and connectivity and a simple enclosure for impressive increase in reliability that the GETS SIMPLER the HMI can be added at perhaps another HMI conferred. The HMI can monitor the There are two kinds of software that are $200-300. On the other hand, a hardwired process of entire system to ensure its used with an HMI. These include engineering operator panel might require a much larger stability. software to design the graphics and screens, enclosure, plus all the individual components, SMALLER, FASTER, SMARTER and the operating programme that allows buttons, indicator lights, switches, relays, Using an HMI has allowed plant engineers, the HMI to fulfill all the requirements of an and associated wiring, for a total of more system integrators and machine builders to operator station. Since most HMIs are than $3,000, exclusive of the labour pre-design libraries of faceplates, indicators, Windows devices, standard programming requirements necessary to install and widgets and objects that can be pulled up languages and standard conventions for connect all those components. together simply on an editing screen. This Windows-based displays can be used DOING MORE THINGS IN A replaces the sourcing, purchasing, pulling including standard hot keys and mouse or BETTER WAY from inventory, kitting, assembling and joystick functions. This means that the pool Not only are the costs of construction, testing procedures that were used with of potential software development installation and maintenance reduced, but hardwired operator panels in the past. Even personnel, whether in the user company or also those associated with operation and a relatively complex batching procedure in the system integrator or machine-builder training are also reduced when an HMI is can be designed on an HMI panel in a company is much larger. In addition, the used instead of a conventional operator matter of days, whereas the old procedure barriers to using HMIs instead of conventional panel. Every operator station in the plant or might take weeks or more. This itself offers hard-wired operator stations are few. manufacturing cell can have the same huge cost-savings for the engineers, TAKING OVER operator interface, which simplifies training integrators or machine builders. Moreover, The Windows- or Linux-based HMI is and reduces the learning curve. HMIs have been getting smaller, faster, essentially replacing the standard operator In addition, training can be enhanced by smarter, and less costly over the last ten panel, even as an embedded controller in using the HMI as a training simulator, years. devices like VFD, PLCs or PACs. These are imparting knowledge on both normal This means that they can be applied to setting the standards for operator interfaces operational and recovery procedures for more sophisticated control problems; can now and in the future. dealing with abnormal or adverse situations. easily replace even a simple H-O-A station; Better training can mean the difference and can do complex mathematics, log data, Hector Lin, Advantech Corporation, Industrial between a short outage while a problem is handle alarm management algorithms, and Automation Group resolved and a long rebuild because the produce sophisticated graphics in real-time.

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EASY

SLIP RING

SPECIFICATIONS TO ENSURE A

A slip ring is an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure. A wellchosen slip ring can go a long way in improving mechanical performance, simplifying system operation and eliminating damage-prone wires dangling from movable joints. Here are six pointers, which if taken into consideration, while specifying a slip ring at the design stage, can ensure the best fit for the application. standard slip ring, also called a rotary electrical joint, collector or electric swivel, can be used in any electromechanical system that requires unrestrained, intermittent or continuous rotation while transmitting power and/or data. It has four components. First is a ring assembly that provides one or more circuit paths. Each ring is electrically conductive and provides a circuit path over a full 360° of rotation of the ring assembly. Next are the brushes that provide electrical contact between the rotating (usually the ring) and the stationary parts of the assembly. The brushes ride on the ring, and are mounted in a brush block assembly, usually on the stationary structure. Then there are the input and output leads that connect the ring and brushes to the outside world. Connectors link to the slip ring assembly wiring. These are optional and often specified by the customer. In the process of specifying a slip ring, following are some of the major considerations that a slip ring engineer

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needs to know about an application. The various applications employing slip rings are: Semiconductor equipment Industrial machinery Robotics Medical equipment Packaging machines Cable reels Laboratory equipment CCTV camera mounts Lighting Rotary index tables Rate tables Medical CT scanners Amusement rides Flight simulation.

SIX BUYING PARAMETERS TO BE CONSIDERED In order to ensure the best performance and efficiency for the given application, it is imperative to make the right choice of slip rings. For this, there are six important pointers that must be kept in mind to help the slip ring engineer at the designing phase

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Electric Slip Rings

itself. These considerations will ensure that the slip ring delivered is one that fits the application best.

Difference between a slip ring ‘capsule’ and ‘separates’ or ‘pancake’ and ‘drum shape’ approach and when to

use which: ‘Slip ring capsule’ and ‘slip ring separates’ are two commonly used terms. The term ‘separate’ indicates an individual rotor/brush

block combination. The term ‘capsule’ is used to denote a self-contained unit consisting of a rotor, stator and its own integral ball bearings. There are two basic slip ring configurations to consider based on space allocation in a system: The more common is the ‘drum’ approach where each ring is adjacent to the next along the centerline, somewhat like the threads on a bolt, and the platter approach where the rings are concentric with one another like the groves on a flat surface. The pancake approach is used when length is at a premium, but diameter is less restrictive. A drum design is more cost-effective and performs better than a pancake design. A pancake slip ring usually has more weight and volume for the same circuits, greater capacitance and crosstalk, greater brush wear and more readily collects wear debris on its vertical axis. However, a pancake offers reduced axial length for the number of circuits. So the decision to use a pancake is usually due to the size and shape of the envelope with which one is working. A slip ring ‘separate’ can sometimes accommodate size constraints or cost limitations better than a capsule. The best bet for ensuring limited rotation is a Polytwist or twist capsule, a reliable slip ring substitute for limited rotation applications – up to 1-1/2 turns of rotational freedom. It resembles a miniature slip ring assembly in size & appearance and provides a selfcontained, no-sliding contact rotary interface using flexible circuit tapes for those applications where continuous rotation is not required. Poly-twists feature low torque, no noise and a long performance life. The relevance of the mechanical envelope and how is it correlated to the space available in the system: The envelope is, of course, largely dictated by the space available in the system. The slip ring engineer should be given the maximum space available in the system so all existing candidate designs can be considered. It is imperative that the space required for the slip ring be specified in the early stages of the system design and that it should be consistent with the structural and electrical demands.

FACFACT T

SLIP RING

Almost any slip ring can operate successfully at speeds upto 100 rpm, although many applications only require operation at a few rpm. But slip rings are also routinely used to instrument jet turbine engines operating at speeds in excess of 20,000 rpm. The operating speed in conjunction with the diameter dictates the surface speed of the brush relative to the ring, and hence, the internal design approach and material selection.

The system interface requirements: The slip ring engineer will need to know these system interface considerations: Is a bore required through the slip ring for routing coolant plumbing, hydraulic lines, pneumatic lines, waveguides, etc? In such applications, the slip ring actually mounts concentric with these lines in the system. How will the slip ring attach to the system? It is never advisable to hard mount both the rotor and the stator to the system since the slip ring bearings may overload, if there is any misalignment between them and the system bearings. How should the electrical connections to the slip ring be made? Is it desirable to have connectors integral with the slip ring on both the rotor and stator, or would flying leads on one or the other ends be desirable? And if flying leads are preferred, should they exit the rotor in a radial or axial direction, and what length should the leads be?

Influence of specification of electrical requirement on the engineering of the slip ring and the range and variety of signals that a slip ring design can pass: The current specified enables the slip ring engineer to propose a unit with the appropriate cross-sectional area of the

Fibre Optic Slip Ring Systems - ﬁbre optic rotary joint (FORJ)

Electro Hydraulic Slip Ring - Fluid Rotary Union (FRU)

rings, brushes and lead wires. The specified voltage dictates the spacing between adjacent rings and brushes. It is helpful in achieving the most cost-effective and smallest practical envelope not to rate all circuits at the maximum level. For example, if one needs 20 circuits total, three of which

The most basic slip ring design can pass power. Poly-scientific slip rings successfully transmit the broadest band frequency transmission – from DC to gigahertz – with absolute data integrity. must carry 10 amp, designate three for high current. Don’t go for 100 per cent functional interchangeability by specifying that all 20 be able to carry 10 amp. There is no reason to pay for 10 amp continuous capacity when one requires only 2 amp. Be aware that voltage surges and spikes are the major cause of system slip ring failures. Despite using a conservative approach to circuit design, it is not uncommon in some power supply systems to see voltage spikes 10 or more times the normal operating voltage. Surge protection on all power supplies is strongly recommended. Most smaller slip rings will satisfactorily conduct signals to 1 MHz or 500 Kilobit. Special slip rings can be used to pass broadband signals from dc to 1 gigahertz and data rates of 500 megabits or

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SLIP RING

even higher. Cross-talk, insertion loss and bit error rate information can be provided, if data rates, formats and impedances are defined. The most basic slip ring design can pass power. Poly-scientific slip rings successfully transmit the broadest band frequency transmission â&#x20AC;&#x201C; from DC to gigahertz â&#x20AC;&#x201C; with absolute data integrity. The mechanical requirements of the slip ring to operate successfully: Operating speeds (rpm): Almost any slip ring can operate successfully at speeds upto 100 rpm, although many applications only require operation at a few rpm. But slip rings are also routinely used to instrument jet turbine engines operating at speeds in excess of 20,000 rpm. The operating speed in conjunction with the diameter dictates the surface speed of the brush relative to the ring, and hence, the internal design approach and material selection. What rotational life is necessary for a particular application? Will the unit oscillate or rotate at a continuous speed?

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Contactless Slip Rings

These factors need to be taken into consideration to ensure successful operation of slip rings. Influence of operating environment on the performance of the slip ring: The environment in which the slip ring must survive is a key factor.

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Many of the slip ring designs and manufacturing processes described are proprietary and are covered under one or more US, European or Japanese patents. The information provided is intended to assist the system engineer in initial discussions and is not intended as a specification. Many slip rings incorporate brushes that wear, and shed debris, spreading contaminants in the unit. Most of the commercial slip rings are available with an optional seal that protects them from dust and splashes. They cannot, however, be immersed in water. If a unit is going to be subjected to wash downs, the slip ring is usually enclosed in a protective housing. Operating temperature is important in specifying the proper lubricant. And if the slip ring operates when exposed to the elements or to a hostile environment, integral seals must be included in the design. Any unusual shock or vibration should also be specified. Sudip Chowdhury, Engineering Manager, Moog (csudip@moog.com) & Anil Krishnan, Sales Manager, Moog (anil@moog.com)

DESIGN & BUSINESS

WHY CANâ&#x20AC;&#x2122;T WE BE

Executives rely on designers to revitalise their businesses, while designers need the support of executives to bring their ideas to market. In spite of such dependability, they stay poles apart in their functioning. However, to attain success in business, they need to co-operate and become productive friends.

ven as design has emerged as a key business theme, with executives broadly wishing for the type of design successes propagated by Apple, JetBlue and Herman Miller, the relationship between designers and business executives has remained distant. Designers make executives nervous by combining what appears to be a lack of interest in rigorous, quantitative analysis with the inclination to propose apparently reckless, radical departures from the past. Executives might love the promise of creativity, yet they find designers hard to take. Designers find executives inexplicably wedded to mediocre status quos and inclined to apply impossibly high standards of proof to design ideas, thus ensuring those ideas go nowhere. On the other hand, designers long for access to the purse strings that executives control, but they find executives almost too conservative to tolerate. It is difficult to manage the relationship between designers and executives because there is a fundamental tension between them, a separation ill-understood by both sides, driving all parties to engage in behaviour that makes the other side nervous and worried. When designers and executives will understand the sources and nature of the divide, they will find each side can take five steps to overcome the

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Illustration By: Sanjay Dalvi

FRIENDS? tension and become productive friends.

FUNDAMENTAL SCHISM The reliability orientation of business executives versus the validity orientation of designers creates a fundamental tension. Because the orientation of each is natural and utterly implicit, neither executives nor designers understand the nature of the gap; they only sense that the other side makes them nervous. Reliability is the result of a process that produces a dependable, consistent, replicable outcome. If a vial of someoneâ&#x20AC;&#x2122;s blood is taken and is split into 100 sub-samples, and run through a testing process for, say, hepatitis, it would be a fully reliable process, if it gives the same answer all 100 times. Validity, by contrast, is the result of a process that produces a desired outcome. For instance, if an entire vial of blood is taken and run through a single test, and the test is negative (positive), which confirms that the person never developed hepatitis, it would be a valid test â&#x20AC;&#x201C; i.e. it provided the outcome desired, the identification of whether or not the person had hepatitis. Reliability is demonstrated by past events: If the same hepatitis test is run 10,000 times and the same result is achieved each time; it can be said that the process is reliable. Validity can only be demonstrated

DESIGN & BUSINESS

by future events through the passage of time: it would be essential to observe that person to see whether he develops hepatitis in the future to assess the validity of the test. Clearly, both reliability and validity need to be perfect. One would expect the test to give the same answer every time, if the person has hepatitis, and to correctly identify Graph 1: A fundamental predilection gap whether or not the person has the condition. Therein lays the fundamental means of the distributions are apart, the problem. After a point, it is not possible to increase curves are overlapping, because some reliability without sacrificing validity, or vice designers are highly reliability-oriented and versa. The conflict between reliability and some executives are highly validity-oriented. validity plays out in the relationship between By and large, all designers long to work with business executives and designers. The business executives who are on the right former are more reliability-oriented on an side of their curve, and business executives average, and the latter are more validitylike to work with designers on the left end oriented. At a conceptual level, the world of of the designer curve. Such situations, business people and the world of designers however, are by definition not the norm in can be represented by the two curves in this dynamics; they are statistical outliers. So Figure 1. The business curve emphasises how do business executives and designers reliability, while the designer curve need to think, and what do they need to emphasises validity. Business executives live do, in order to overcome the fundamental in an environment that rewards meeting schism and be the most productive friends budgets, hitting earnings targets and they can be? ‘proving’ in advance that their initiatives will HOW TO OVERCOME THE succeed. Their number one analytical tool FUNDAMENTAL SCHISM is linear regression, because it helps them Given below are five pieces of parallel substantiate reliability on the basis of past advice for designers and executives to tackle results – if it has always happened in the the situation effectively: past, it will also happen in the future. That’s Designer Advice #1: Take inattention to the primary substantiation for reliability, so validity as a ‘Design Challenge’ the average business executive has the Designers generally love nothing more than incentive to be more reliability-oriented a tricky and complicated design challenge, and will be trained in methodologies that so that they can create a marvellous solution produce reliability. where one doesn’t currently exist. But their Designers possess an inherent bias reaction to the organisational challenge of towards validity. Great designers seek deep dealing with inattention to validity by understanding of the user and the context, corporate executives is often quite entailing the consideration of many variables. unproductive. Rather than taking this They don’t limit considerations to aspects organisational issue as a design challenge that can be thoroughly quantified. They and putting their design hats on to create a worry less about whether they can replicate process to solve this problem, they are a particular process and more about inclined to simply complain about reliabilityproducing a valid solution to the problem oriented executives and dismiss them as before them. The only proof they tend to philistines who can’t appreciate what needs accept is future-oriented i.e. a design to be done. In a sense, they define the solution shown to work with the passage of reliability-orientation of executives as ‘not time. Reliability orientation causes business their problem’ – just an immovable executives to say to designers, “You’ve got constraint. If, instead, they treated the actual to quantify it, you’ve got to prove it.” The existence of ‘design unfriendliness’ designer in response says, “Prove it? How (inattention to validity) as being as important can you prove something that can only be and legitimate a design challenge as their substantiated by future events? You can’t! If normal job of designing an artifact – product, you insist on proof, you’ll never do anything website, corporate identity, user interface impressive.” – they could be more productive and Coming back to graph 1, while the

effective in working with executives. Inattention to validity is and should be treated as just another design challenge for the designer, to be tackled with the same energy and enthusiasm they apply to traditional design challenges. Executive Advice #1: Take inattention to reliability as a ‘Management Challenge’ Executives generally love nothing more than taking the confusing and ambiguous world in which they operate and organising it into a reliable operation. But their reaction to the challenge of dealing with designers’ inattention to reliability is often quite unproductive. Rather than taking this as a management challenge and putting their managerial hats on, they are inclined to complain about flighty and impractical designers and marginalise their work, so that it doesn’t threaten organisational order. Executives see the validity orientation of designers not as a legitimate management concern – but as a threat to security and stability that ought to be extinguished. If, instead, they treated inattention to reliability as being as important and legitimate a management challenge as their normal job of managing an organisation, they would be more productive and effective in working with designers. Inattention to reliability is and should be treated as just another managerial challenge for the executive, to be tackled with the same fervour and enthusiasm they apply to traditional management challenges. Designer Advice #2: Empathise with the ‘Design-Unfriendly Elements’ The only way to design a compelling solution for a user is to understand the user in a positive way. It’s almost impossibly hard to design something compelling for a person the designer doesn’t respect or attempt to understand. In contrast, an effective designer attempts to achieve deep understanding of the user to uncover the greatest range of options for creating a compelling solution. What are the user’s greatest hopes? What are the minimum acceptable conditions for the user to embrace a design solution? How much risk is the user willing to absorb? The designer can answer these questions with either empathy or disdain. The ineffective designer sees that what keeps the user up at night is the desire to keep his or her proverbial mentality under wraps. The effective designer sees that what keeps the user up at night is a desire to

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DESIGN & BUSINESS

protect assets and employees from the consequences of a reckless decision. In the case of the schism between the world-view of the designer and the executive, a better understanding of, and empathy for the executive’s point of view enables the designer to probe what constitutes a reckless decision versus a sensibly aggressive decision – from the executive’s viewpoint. Only with such empathy can the designer forge a solution that meets the executive’s needs in a productive way. Executive Advice #2: Empathise with the ‘Reliability-Unfriendly Elements’ Likewise, the only way an executive can create an organisational context in which designers can work productively is to empathise with them. They are not being purposely worrisome; they are attempting to tackle the problem of having to make sense out of fuzzy data, qualitative insights and judgements. Designers see things executives don’t see and are doing their best to deal with complexity. Only by empathising with designers and really understanding their concerns and ways of operating can the executive devise managerial structures that take into account both the needs of the organisation and needs of the designers. Designer Advice #3: Learn and speak the language of reliability To empathise, one needs to communicate. But executives and designers speak different languages. Executives speak the language of reliability because they put a high priority on producing consistent and predictable outcomes. They use words like proof, regression analysis, best practices, and deployment. Designers speak the language of validity; they thrust on producing outcomes that delight, whether those outcomes are consistent and predictable or not. Designers use words like visualisation, prototyping, beta-testing, novelty, etc. To executives, latter words connote danger, uncertainty and guesswork. It is incumbent on the designer to learn the language of the executive – the language of reliability. Executive Advice #3: Learn and speak the language of validity Both sides need to engage on the same platform – learning one another’s language. The executive needs to learn and speak the language of validity. Executives will not get productive innovation from designers, if they force them to exclusively speak the language of reliability. It is incumbent on executives to learn the language of validity,

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so that they can actually communicate with designers. Designer Advice #4: Use analogies and stories What tools help bridge the language gap? It’s difficult to provide proof or certainty, even when designers appreciate that those words loom large in the executive’s reliability lexicon. When executives care primarily about substantiation based on past events and designers care only about substantiation based on future events, designers have a challenge communicating ideas compellingly. The best tool available is analogy – crafting a story that takes an existing idea in operation elsewhere and shows how it’s similar to the novel idea being proposed – not necessarily exactly the same, but close enough. This doesn’t eliminate the risk of an idea, but it presents the risk in a reliability-oriented framework. An analogy or story helps the business executive see that this is not a case of substantiation based exclusively on future events, because the solution is also based in part on past events. In the end, executives will need to convince themselves that the idea falls into an acceptable range of reliability if they are to adopt it. Executive Advice #4: Share date and reasoning, not conclusions The inclination of reliability-oriented executives is to crunch all the data they see as relevant, come to a firm conclusion on the analysis, then impose that conclusion on everyone else (including designers). Listening to this, designers think that what the executive sees as all of the data is only a small fraction of the relevant evidence, and that the executive is overlooking or consciously ignoring other evidence that is hard to measure and quantify. When executives try to impose their conclusions on designers, they cause designers to feel that it is impossible to develop a truly innovative and superior solution – too many of the important features are being ignored. But if executives don’t share their data and reasoning with designers, the designers won’t understand what executives are thinking, and that will make it harder to create an acceptable design solution by executives. This is because executives, sharing data and reasoning, but stopping before imposing conclusions helps designers come up with a solution that can elicit an immediate positive response. Designer Advice #5: Bite off as little a piece as possible to generate proof

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Even with careful use of language and employment of analogies, generating proof is the biggest hurdle for designers. Unlike executives, they don’t put thrust on reliability-oriented proof or substantiation based on past events. Designers can’t simply prove in advance that their ideas will work. From a proof standpoint, what happens in the future is not relevant. The good news is that a year from now, this year will be in the past. This nuance is critical to reliabilityoriented executives. Designers can convince executives to bite off a piece of what they would like to do. If the executives agree to that, and the designers’ predicted results happen, it builds confidence. The key for designers is to turn the future into the past because ‘future’ is the enemy to a reliability-oriented executive and ‘past’ is a friend. Designers don’t love the notion of biting off a little piece, because they feel any phasing of the solution will destroy its integrity. Most designers would rather have everything done in one swoop and not look back. But designers need to develop skills in biting off as little a piece as possible to give themselves a chance to turn the future into the past. Executive Advice #5: Bite off as big a piece as possible to give innovation a chance Executives have to listen to designers when they say, “We will have to do ‘this much’ of this idea or we won’t really know whether it will work.” Doing ‘this much’ may be a frightening notion when not much reliabilityoriented proof is available. But just as the designer has to stretch to bite off as little a piece as possible, the executive must stretch to bite off the biggest piece possible – without feeling he/she is being irresponsible.

REACH OUT AND BE FRIENDS Advice for improving relationships is always generic – appreciate that there are legitimate differences, empathise, seek to communicate on others’ terms, use tools with which they are familiar, stretch out of one’s comfort zone towards that of others. Getting along has never been and will never be rocket science. That doesn’t prevent the world from being full of conflicts, though, like in the uneasy relationships between designers and business executives. Yet these relationships can and should be highly productive. And they can be when both sides reach out and make friends. Roger Martin, Dean, Rotman School of Management

INNOVATORS’ OUTLOOK

THE POWER OF INDUSTRIAL DESIGN IS REALISED NOT BY AN AMAZING IDEA, BUT BY THE ABILITY TO DELIVER IT “The first step towards design success lies in understanding the potential of a design,” asserts Jashish Kambli, Executive Partner – Design & Development, Future Factory in an interview. Excerpts...

ESIGN INNOVATION ADVANTAGES

Design innovation can provide a game-changing advantage for businesses, but for the same reasons it has a strong element of risk. Only the companies that understand and mitigate the involved risks will be able to constantly support as well as undertake R&D efforts. However, since most Indian firms are unable to assess the risk, it is hard to correctly estimate the required amount of resources. Inevitably after a certain amount of experimentation, they withdraw funds and resources, and as

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a result, innovation fails. In order to prevent such situations, it is important to ensure an accurate way to estimate all the risks involved, and plan accordingly. Alternatively, investments are essential that can cover the uncertainties associated with an innovation activity.

LATEST TRENDS IN DESIGN THAT CAN DRIVE THE GROWTH OF INDIAN SMEs Generally, specific trends are witnessed in different industries. However, a recent tendency has been to apply existing technologies to new applications. In the IT industry, leading companies have their

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own ‘future technologies’ division that focusses on application rather than invention. In the consumer industry, the trend has been to apply new finishes to existing materials. The SMEs can adopt such strategies, as it doesn’t demand investment in R&D. If SMEs are able to keep themselves updated with new materials that are available, they can gain a competitive edge.

THE PERFECT MIX TO CREATE A SUCCESSFUL AND WINNING DESIGN The power of industrial design is realised not by an amazing idea, but by the ability to

INNOVATORS’ OUTLOOK

deliver it. Most Indian design firms are design talent required to make ‘Designed in product in 6 weeks, his Indian counterparts unable to see their designs through India’ dream achievable. ‘Made in Japan’ deliver the same specification in 10 weeks. development and manufacturing, with the became a desired tagline only after serious While this wide disparity can be addressed result that wonderful concepts eventually and consistent efforts at different levels, be it by dealing with infrastructural bottlenecks, translate into ordinary products. The perfect at the infrastructural level or processing/ managing labour and streamlining processes; mix for a design firm is to complement manufacturing or marketing levels. what is also needed is a change in mindset. creativity with skills on application of Companies also need to meet tight DEVELOPMENT OF NEW materials, processes, and even deadlines always. MATERIALS/APPLICATIONS Investment manufacturing. At ‘Future Factory’, we run AND THEIR IMPACT ON Innovation in the area of design often design hand-in-hand with development DESIGN calls for investments. While R&D budgets teams to materialise the designs into Materials and processes are key to are usually significant enough; they focus on products right to the end. Taking responsibility for the innovation, and today, there entire process is key to creating are many global resources that To create a breakthrough design, a combination of focus on their application across winning designs.The first step towards design success lies in creative thinking with correct application of materials industries. For example, it is understanding the potential of a possible to print printed circuit & manufacturing processes is a pre-requisite. This will boards (PCBs) on new clothing design. Most businesses see enable the development of amazing designs that actually materials today. What is key design only as a winning aesthetic, but design can do work and deliver the promise they were meant to, and here is the innovative much more. It can create application, not just the ensure the success of innovation. innovations, reduce the cost of development of the new manufacturing, improve quality, material itself. inventing new formulae or developing new streamline sourcing, and even reduce CATALYSTS FOR DESIGN patents and little money is put into inventory. Understanding and exploiting DEVELOPMENT TODAY application of R&D to product design. the potential of design will lead to design Design efforts can gather speed by increasing Design initiatives that use these patents to success. To make this happen, there is a exposure. This exposure may be across create products faster and in large numbers need for design voice – someone in the industries or markets. Essentially, our design will help in resolving these issues. Only such organisation who can push design to efforts at Future Factory are always crossefforts will provide increased business deliver the best of products. Through functional and across industries. So an idea returns for the client and make it a profitable design innovations, companies can not used in one application can be innovatively venture. only gain marketshare but also build brand Design talent applied to a completely different application. power. India has too few design schools of At a larger level, multi-industry and market FIVE FACTORS THAT WOULD repute. To become a powerhouse in design, collaboration would produce the same LEAD INDIA TO BECOME A it is vital to have talented designers, who are results. DESIGN HUB OF THE WORLD trained to work in commercial environments Today, India is at the centre of the world’s PROSPECTS FOR INDIAN and meet client expectations, besides INDUSTRIAL DESIGN SECTOR focus as a market. It can use this opportunity creating award-winning work. While effort The Indian industrial design sector holds to become a focal point of product in spinning of new schools will help; it is the promising prospects across all verticals. innovation and design. But for this to maturity of the industry that will create real However, the rising importance of the happen, the country needs to address the talent, and create it in enough numbers to renewable energy sector; the high growth following: fuel a growing design industry. Quality of manufacturing Policy potential of sectors such as IT & telecom, Design capabilities will reach new Indian designs inevitably have a and of course, the scale of the consumer heights, if the governmental and regulatory compromised finish, a less than perfect segment are expected to open up new bodies give a thrust to the design aspect. quality. To design a great product, there avenues for design. Often policy change can help a company must be an assurance of great quality. CREATION OF AN to become a powerhouse. In the recent Unfortunately, in many Indian businesses, INNOVATIVE past, Indian designers took the initiative to the problem is compounded by either low BREAKTHROUGH PRODUCT push design policy at the government volumes or lack of industry expertise. While To create a breakthrough design, a level, but the benefits are yet to be design can address these issues by combination of creative thinking with realised. understanding process limitations, what is correct application of materials & truly needed is progress at the manufacturing REALISING THE ‘DESIGNED IN manufacturing processes is a pre-requisite. end. INDIA’ DREAM Speed to market This will enable the development of amazing According to me, it will take at least 6 years Indian businesses are known to take designs that actually work and deliver the before the industry matures enough to inordinately long for most processes. For promise they were meant to and ensure promise the quality, speed to market, and instance, if a UK manufacturer delivers a the success of innovation.

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PLASTIC TO FUEL

‘FUEL’ FOR

THOUGHT

Perhaps now the environmentalists, who were complaining about the increasing plastic menace, can breathe a little easy. MK Aromatics, a Chennai-based firm, has come up with a sustainable solution by adopting the polymer energy technology, which converts plastic into crude oil. By doing so, they have proposed an innovative business model for companies and policy-makers, which would not only provide economic benefits, but also ascertain a healthier environment. Illustration By: Sanjay Dalvi

SANDEEP PAI

he increasing use of plastics for various purposes, particularly packaging, has led to an exponential growth in its demand. However, when it comes to the disposal of used plastics, it has been seen that the existing waste management methods such as landfill disposal, incineration and recycling have failed to deal with the growing plastics menace. As the recycling process is difficult and costly, most of the plastics end up in landfill sites where they take around 300 years to photodegrade. Here, they break down into tiny toxic particles that contaminate the soil and

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waterways, and enter the food chain when animals accidentally ingest them.

CHALLENGES CONFRONTED BY INDIA During the early days, the landfills were located away from the cities and so their environmental impact was less felt. But, as the city boundaries are expanding rapidly, these landfills have reached the periphery of cities, causing huge environmental problems. Therefore, the search for new and large landfills has been the focus of policy makers for sometime now, but with meagre success. Apart from plastic waste disposal,

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another grave problem confronting the nation has been that of price rise caused due to the shortage of fuel worldwide. India being an oil importing country, the repercussions felt here are even more. Price rise has impacted almost every industry in India – from manufacturing to logistics. Several eminent environmentalists, economists and government agencies are treating these as two independent problems. Rightly so, as there is no direct correlation between them, except that they need serious intervention. Development has a price attached to it, both monetary & environmental. And the new age solutions are all about turning the

PLASTIC TO FUEL

problems into solutions. Now imagine a situation wherein plastic waste can be converted into useable fuel. With regards to the feasibility of such a possibility, MK Merchant, CEO, MK Aromatics, and an environmentalist, informs with pride, “We feed 7 tonne of plastic, and produce approximately 7,000 litre of useable crude oil a day.” MK Aromatics and Harita-NTI, a joint venture company between TVS and Northern Technologies International Corporation (NTIC), US, have come together in setting up the first polymer energy plant in South Asia in Alathur, Chennai. With only one machine in operation currently, the plant runs on an extraordinary technology that converts plastic into crude oil. Merchant believes that it is just the beginning and the country needs to implement this fascinating technology in other regions also. “We hope to make a difference, and most importantly, make our country green and clean,” he adds. Plastic wastes from 1,700 companies of Ambattur Industrial Estate Manufacturers Association (AIEMA) are collected in two containers placed in the north and south of the industrial estate. Collection of waste is done by Max Landfill Solutions, which also collects additional wastes from in and around the city by placing proprietary containers designed specifically to carry plastic waste. For this purpose, trucks are deployed to procure the waste plastic. After

regular collection, the waste goes to a 24hour processing centre operated by MK Aromatics. The project has hugely contributed in making the estate clean and green, and helped the unit holders to drain the storm water and sewage lines, which used to stay blocked due to accumulation of plastic waste.

POLYMER ENERGY TECHNOLOGY

During the operation, a process called catalytic pyrolysis is used to efficiently convert plastics to crude oil. It provides an integrated plastic waste processing system, which offers an alternative to landfill disposal, incineration, and recycling while also being a viable, economical, and environmentallyresponsible waste management solution. The modular plant design allows for scalable capacity, with each unit capable of processing up to 7 tonne of waste plastic per day.

The polymer energy technology was WORKING PROCESS AND developed by Polish engineer Zbigniew MAINTENANCE Tokarz and has won several industry awards, In fact, one of the key advantages of this including the prestigious 2006 European system is that the process can tolerate high Environmental Press Award for innovative amounts (up to 30 per cent of the mix) of waste management solutions. other contaminants in the input plastics Environmentalists believe that it is a groundwaste stream. Talking about the kind of breaking, proprietary process to convert plastic that is being fed, Merchant says, waste plastics into renewable energy. The system is robust by design and can easily process typical plastic Typically the polymer energy system can waste such as used agricultural/ process plastic waste with up to 30 mulch film, silage wrap and other soiled agricultural plastics, per cent of the following contaminants: metallised plastics, plastic Mineral impurities such as sand, dirt, etc laminates, printed plastics, wet Impurities such as glass, small metal parts plastic by-products and even heavily recycled plastics. The Impurities such as cellulose, clothing technology ensures that nonWater, oil residue and so on. plastic contaminants are converted into ash and are “Excluding polyvinyl chloride (PVC) and automatically removed from the system PET, any form of waste plastic, be it low during the normal cleaning cycle of the density polyethylene (LDPE), high-density system. polyethylene (HDPE) or propylene, can be fed as input.” System Data The salient feature of the chemical plant Polymer Energy is that the waste plastic does not require Process Random Depolymerisation (Selective breaking of carbon to carbon much segregation or sorting. “This helps in bonds) saving time and resources. Moreover, the Input materials Plastic waste and catalytic additives operation is not labour-intensive, and we Plastic conversion results Liquid hydrocarbons, coke and gas coke is further processed to produce have qualified staff on site along with plant liquid hydrocarbons and diesel managers to see that the operation runs Volume produced 720 litre per tonne of plastic waste processed* non-stop. Also, we have sorters on premises, Energy ratio Up to 18 (for every BTU input energy, 18 BTUs are produced) who inspect the plastic to ensure that PVC Operating commercial sites Qty Size Location and PET are not present,” he asserts. 11 10 MT Poland & India The main part of the system is the Sites under construction Qty Size Location reactor, which is the heat-transducing 12 10 MT India, Thailand, Germany, Slovak device. The reactions that take place inside Republic and Poland are based on catalytic de-polymerisation. Feed system Assorted packaging materials are fed directly into the reactor. Materials such as car bumpers or dash boards and battery casings require crushing The waste processing is carried out under prior to being fed into reactor hot condition in atmospheric pressure Pre-melting feeder under no air conditions. The heat is supplied Melting The reactor melts and vaporises plastic in one step between 450° C and in a number of individually controlled 550° C. Waste extraction is automated. Reactor heating zones for better results. Waste extraction During the process, some by-products * Results will vary based on moisture content, impurities and type of plastic in each tonne of plastic. such as carbon dust and C1 to C4 gas are Calculations are based on 15% moisture and other waste products mixed with plastic. produced. However, even this doesn’t harm

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PLASTIC TO FUEL

Unique features of the Polymer Energy System The system is designed to process the following types of plastic waste polyethylene (LDPE, LLDPE & HDPE), and polypropylene up to 5 per cent of other types of plastic tolerated. The reactor can tolerate contaminants such as glass, paper, soil, metals, and moisture. One modular design allows for easy installation and plant expansion. Capacity of each module is typically 350 tonne of waste plastic per month. Output of each module is close to 1000 litre per tonne of waste plastic processed. the environment, thanks to inherent features of the machine. The C1 to C4 gas is fed back to the reactor to maintain the temperature. Even the generated carbon dust is converted to carbon cake, which is also used as coke. Moreover, no extensive maintenance is required for operating the plant. To ensure that the entire process works efficiently, MK Aromatics has deployed environmentally conscious and dedicated supporting personnel. “Our staff ensures that the entire process runs safely, standards are maintained and there is minimal wastage of resources,” Merchant adds.

BUSINESS MODEL – OPPORTUNITIES FOR THE COMPANIES While the plant has been contributing immensely towards environment protection, it has proved to be a successful capital generating business model for MK Aromatics. “Our business model is based on our corporate vision and goals. Our core focus is on the environment, however, profitability is of importance for the company to remain in business. Hence, we have adopted a sustainable business model that not only produces economic profit,

ADVANTAGES OF POLYMER ENERGY ENERGY

The energy trapped in plastic wastes is released and refused, thereby reducing fossil fuel demand. Benefits: Co-generation & carbon credit

ENVIRONMENT

ECONOMY & SOCIETY

Reduction of plastic wastes Benefit: Saving in landfill space

Conversion of plastic wastes into profitable product & employment opportunities Courtesy: Xybernetizen Incorp

Once the process is complete, then the generated high-grade crude oil is further processed in a refinery, if required. However, it is used directly to power lowrpm machines such as electric generation turbines. “No further refining is required before usage. Some of our customers request for unrefined product. Sometimes, however to add value to the product, we further refine our product,” says Merchant. The quality of the end-product is superior from what is available in the market, claims Chennai Petroleum Corporation (CPCL) officials.

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but also creates social capital,” says Merchant. According to S Baskaran, EC member, AIEMA, the technology is proving to be a successful business model for companies to invest. According to Xybernetizen Incorp, the total investment required for installing the machine is Rs 10 crore on a turnkey basis. This amount can be recovered in five years, as more than Rs 200 lakh can be generated per annum if the plant runs to its fullest capacity. Moreover, the land required for setting up the machine is in the range of a few acre. Even the energy required to run

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the process is just 30 litre of heating oil per hour and approximately 30 KW of electrical energy. Harish Padiyath, CEO, Harry and More Consulting, proposes unique ways by which companies can take up this project, “Interested entrepreneurs can tie-up with various municipalities other than industrial houses to get the waste plastics. In return, they can offer cheap fuel for running machines.” Even joint ventures can also work out – one company can operate and other can collect, he adds. The two main sources of scrap plastic in India comprise consumer and industrial wastes. Both can be targeted for getting inputs for the plant. The consumer wastes include the household, hospital and street wastes. And as the name indicates, industrial waste includes all the waste plastic from industries. “With population growth and rise in the number of industries, both types of waste are bound to increase, making this a lucrative sector for the companies to invest,” says Padiyath. Apart from the companies, even the municipalities can adopt the technology to contribute from their end. Some progress has already been made in this regard. Cochin and Mysore municipalities have shown keen interest and are considering buying a few of these machines. “Various municipal corporations have been approached and discussions of joint ventures are on. They look quite promising,” avers Merchant.

WAY FORWARD The future of this technology in India is endless as the consumption of plastic is at an ever-increasing pace. It was estimated that India generates 29 million tonne of waste plastic per year. If all this plastic (excluding almost equal amount of imported waste dumped in India) can be converted into fuel, then the country can save around Rs 11,081.4 crore every year, reveals the Xybernetizen Incorp report. This will help in bringing down the fuel prices and would also take care of hazardous plastic waste as well, observes Padiyath. Clearly, hazardous plastic waste converted without emitting any pollutants would be a cheaper partial substitute for getting rid of India’s fuel. This breakthrough invention shall lead to the development of simple and economically-viable technology for environment-friendly disposal of waste plastic.

Illustration By: Sanjay Dalvi

LEAN PRACTICES

Increasing complexities of business processes coupled with economic pressures are forcing companies to perform more with less. These concerns have led many organisations to follow a ‘lean’ approach for maximising customer value while minimising waste, along with optimal resource utilisation. All industries are now implementing lean principles as the way to think ahead and deliver the best. ean businesses constantly manufacturing segments. operational costs and encourage sustained seek to make their In reality, though, the core premise of improvements. Moreover, all SMEs, operations as efficient and lean is that any company can work to irrespective of their industry, can use lean cost-effective as possible enhance customer experiences, improve principles to enhance efficiency. while delivering value processes & information flows, decrease However, SMEs cannot rely solely on to their efficiency tools and techniques. customers. However, as the They need to adopt a ‘lean A lean mindset pays tangible dividends, even for mindset’, considering the concept of ‘lean’ originated in the auto industry, many companies with a limited scale. For an SME, the business principle that ‘everything starts small and medium enterprises focus becomes sharper after the company commits to with the customer’. Having (SMEs) assume that such defined the needs and articulating and nurturing a shared understanding of expectations through the approaches are suitable only for business goals and values. large-scale companies or customers’ eyes, lean SMEs can

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LEAN PRACTICES

ensure continual improvements in operations and processes to deliver value to the customer in the most effective way.

OPTIMISING OPERATIONS

QUICK TAKE SMEs, irrespective of their industry, can use lean principles to enhance efficiency. SMEs have a wide latitude to adopt a lean approach to their operations and processes. SMEs could increase customer satisfaction and possibly cut costs by eliminating waste and reducing the time between order entry and product delivery.

With a lean mindset in place, SMEs will have a common lens through which all employees can try to identify problems in current business activities, pinpoint the basic reasons help employees project the amount of extended supply chains to share knowledge and develop co-ordinated solutions. material that will be needed, thereby and best practices. For example, inventory In each case, improving the performance optimising inventories and ensuring that replenishment systems that connect of SMEs against relevant performance customer shipments do not face any suppliers directly with points-of-sale can gauges is the objective – from internal scarcity. provide SMEs and their suppliers with financial measures like return on investment SMEs can also make lean changes in greater visibility into actual demand. This (ROI) to external benchmarks like peertheir business functions and organisations. will, in turn, help them to manage group customer satisfaction ratings. Some Typically, financial activities are a prime target inventories efficiently and cost-effectively, SMEs may also prefer to focus on less for efficiencies. For instance, by closing and ensure that customers are not formal, yet compelling, mission statements, month-end books more promptly (e.g. one disappointed by stock-outs. This insight can for example, a pledge – ‘to satisfy customers, week rather than three weeks after the also provide stakeholders with a knowledge not sell products’. of the current business climate Lean SMEs can also use the With a lean mindset in place, SMEs will have a common and act as an early warning customer value perspective to lens through which all employees can try to identify indicator when demand is minimise waste. In a service changing. Technology can be a problems in current business activities, pinpoint the valuable tool for facilitating and business, for example, basic reasons and develop co-ordinated solutions. optimisation may mean assigning sustaining such interactions. an entire end-to-end activity to TOWARDS A LEAN FUTURE an individual or a team to mitigate customer month ends), an SME can make key On a daily basis, a lean mindset pays tangible grievance and increase satisfaction. In a decisions on operating variables such as dividends, even for companies with a limited manufacturing environment, an SME might inventory levels, which have a direct impact scale. For an SME, the business focus improve individual steps in the assembly on the efficiency of the working capital. becomes sharper after the company line to accelerate production (and thus time Similarly, establishing processes of lean commits to articulating and nurturing a to market). In fact, SMEs have a wide expense management and budget approval shared understanding of business goals and latitude to adopt a lean approach to their can quickly reveal unnecessary, misguided values. This helps all employees to prioritise operations and processes. It may involve and excess expenditure. This creates their activities. It also provides a perspective targeting intrinsic operational bottlenecks potential for cost-cutting and funding on more strategic decisions, such as for like poor co-ordination, variability and efficiencies, even in companies that may establishing sourcing or other partnerships inflexibility, each of which has the potential believe they are comparatively small to to separate non-core activities. to increase costs and undermine customer require such formal frameworks. Operations and processes will also relationships. TECHNOLOGY AS AN become more efficient and help to control ENABLER RATIONALISING PROCESSES costs, besides improving customer Lean SMEs can rationalise processes Certain technologies can help optimise responsiveness and satisfaction. A lean SME themselves, irrespective of the processes operations and processes in SMEs. For should also be able to adapt to market being integral to their value proposition instance, SMEs can leverage technology to conditions and customer demands in a (e.g. handling a customer query) or ensure seamless interaction between flexible way, with proper sharing of supporting core activities (e.g. at the back disparate point solutions such as electronic knowledge and best practices. office). For example, to eliminate ‘waste’, data interchange, web and proprietary As a result, lean thinking and practices SMEs can target any activity that creates resource planning tools. Without such can deliver a wide range of performance costs that cannot reasonably be passed on interaction, transaction times with customers improvements to SMEs from better to the customer, or that reduces the value and suppliers will be slower and more customer relationships to greater customers place on the business relationship. costly. operational efficiency and cost management. For instance, wait times are a common area Furthermore, information technology In the long term, this is likely to make the of waste in retail customer relationships. (IT) can be a powerful tool for information business more competitive & innovative Hence, SMEs could increase customer sharing in lean SMEs. After all, the purpose and enable better scaling up & down for satisfaction and possibly cut costs by of applying lean principles is to reduce costs, business cycles, hence resulting in improved eliminating this waste and reducing the time enhance quality and customer experience. returns and greater endurance for the between order entry and product delivery. Lean SMEs will be in a better position to business. Manufacturing and other SMEs can deploy capture these benefits, if they encourage Courtesy: The Economist Intelligence Unit material requirement planning systems to employees and other stakeholders in their

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ELECTRONICA + PRODUCTRONICA 2010

ALL SET TO ENERGISE THE

ELECTRONICS INDUSTRY The electronics industry in India has made rapid strides in recent years, accounting for the production of electronics items worth over Rs 200 billion annually. With an aim to accelerate this growth in India and Southeast Asia, and capitalise on the lucrative business opportunities, Messe München International (MMI) and its subsidiary, MMI India, with SEARCH as the media partner presents electronica India 2010 and productronica India 2010 at the Bangalore International Exhibition Centre (BIEC) from September 7-10, 2010. PURNA PARMAR he electronics industry in booked their space at the show.” In addition, Technologies, Sumitron, Sony, Transtec, India is witnessing East India Technologies, Essemtec Ag, Tyco, and Unified Electronics are other tremendous growth, and Farnell, Harting, Hical, INetest Technologies, major companies that will display their investments are flowing in Infineon, Juki, Ito Precision, Kaynes, innovative product offerings during the to augment its Leaptech, Millenium, Maxim SMT, event. He further adds, “We are looking at manufacturing capacity. NMtronics, NXP, Prosem, Rabyte, RS a strong media campaign in the run up to The output of the electronic hardware Components, SM Electronics, SLN the show for visitor promotion as well.” industry in India is worth The event, considered $11.6 billion at present. In a to be the number one bid to provide further thrust show for the electronics The exhibits to this performance, industry, will be organised Photovoltaic elements electronica India 2010 and by Messe München Feedstock productronica India 2010, a International and its Consumables (paste, wires, etc.) leading event for the subsidiary, MMI India. electronics industry in India IPCA, the co-organiser, Gases and liquid chemicals and Southeast Asia, will be Department of Information Solar glass and encapsulation held at the Bangalore Technology, Ministry of Equipment for wafer-based photovoltaics International Exhibition Communications & Ingot and wafer production Centre (BIEC) from Information Technologies, Cell production September 7-10, 2010. and over 15 industry Module production Providing a perspective on associations will offer the upcoming event, Thomas tremendous support to the Equipment for crystalline photovoltaics, miscellaneous Loeffler, Deputy CEO, show. Equipment for thin-film module production electronica India & Deposition equipment (CVD, PVD) EVENT productronica India, states Equipment for new generation solar cells HIGHLIGHTS “Over 60,000 sq ft of space is Since 2009, the show has already reserved for Equipment for manufacturing photovoltaic modules been divided into two electronica India 2010 and complementary sections – productronica India 2010. Visitor profile productronica India Leading companies in the Central and state government officials devoted to production electronics industry like ASYS, Manufacturers technologies, surface Aqtronics, Agilent Solution providers mount technology (SMT) Technologies, Agate & Agate, and electronic Arrow, Amararaja, Bergen Academic institutions manufacturing services Systems, Bergen Associates, PV System consultants ( E M S ) / c o n t ract Digital Circuit, EMST R&D professionals, academicians and students. manufacturers, printed Marketing, and Epcos have

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ELECTRONICA + PRODUCTRONICA 2010

circuit boards (PCB), solar & PV, laser; and electronica India deals with components, semiconductors, assemblies, LED and materials. In an initiative to provide added advantage under one roof, the 2010 show will also feature a special focus pavilion for solar tech and photovoltaic. Companies from over 25 countries including Germany, Taiwan, Singapore, UK, Hong Kong and China will participate in the event. Two high-profile conferences on ‘Electronics Manufacturing Services’ and ‘Trends & Future Requirements in Automotive Electronics’ will be held concurrently with electronica India 2010 and productronica India 2010. Terming this event as a differentiator, Bhupinder Singh, Project Director, electronica India & productronica India, avers, “electronica India and productronica India have proven to be the number one electronics trade show in India and South Asia. The exhibition clearly demonstrates its close links to the world’s leading trade fairs electronica and productronica in Munich. This will give a boost to the Indian electronics industry in the coming years.” He further observes, “electronica India 2010 and productronica India 2010 is one

of the best promoted brands in India, which is why in 2009 when most of the shows experienced a shortfall in visitor turnout, the show managed to receive over 15,000 visitors from all across the world. In 2010, the number of visitors is expected to be much higher than last year.

SPECIAL PAVILIONS With huge prospects in the solar energy segment, electronica India and productronica India will represent this important sector in a special ‘Solar Pavilion’ including a forum on PV technology. Another special area at this year’s show will be the ‘Laser Pavilion’ in Hall 1. There will also be a new pavilion in the framework of electronica India 2010 – the ‘LED Pavilion’.

PV AND SOLARTECH AREA AT THE EVENT With an abundance of non-depleting and environment-friendly renewable energy resources such as solar, wind, biomass, hydro, cogeneration and geothermal, India is at the threshold of rapid growth in PV adoption and manufacturing. The country has abundant solar resources in the world,

with 2,097 million square kilometre of tropical and subtropical land and an average of 250-300 sunny days a year. The Government of India aims at a double-digit growth in this sector, which in turn will make India the world’s fourth-largest photovoltaic cell and module producing country. It is believed that the recent government initiatives, geographical advantages, existing industrial and research infrastructure and enormous market potential in the country are destined to bring in transformational changes in the solar PV segment.

PERFECT PLATFORM TO PROFIT electronica India 2010 and productronica India 2010 provides a lucrative platform for exploring business opportunities, learning about diverse innovations & varied technical details, and expanding business. Moreover, the event is a must attend for all those who aim at selecting appropriate solutions from a wide range of products and innovative technologies from around the world; leveraging on buyer-seller meets; and sharing knowledge.

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LEADERSHIP THROUGH INDUSTRIAL DESIGN

With a geographically widespread consumer base having varying preferences and habits, it is imperative for companies to come up with innovative product design solutions to become globally competitive. With a vision to provide insights on the various aspects of industrial product design and the ways to overcome the existing challenges, a conference on ‘Leadership Through Industrial Design’ was organised on July 15 and 16 by the Confederation of Indian Industries (CII) in Mumbai. A report... SANDEEP PAI

Pradyumna Vyas, Director, National Institute of Design, delivering the theme address during the conference on ‘Leadership through Industrial design’.

n the globalised world where there is acceleration in the pace of business processes; client and customer demands for immediate outcomes; and cultural intersections define context, there are increasing product demands. In such a scenario, it is imperative for companies to focus on creating ground-breaking product designs that can satisfy customers’ expectations. Hence, the need of the hour is to manage the design capabilities for the future. To highlight the importance of product design, CII, under the aegis of the Department of Industrial Policy and Promotion (DIPP) and India Design Council, and in partnership with National Institute of Design (NID), Industrial Design Centre –Indian Institute of Technology (IIT), Bombay and Indian Institute of Science, Bangalore, organised a conference on ‘Leadership Through Industrial Design’ in Mumbai. The objective of the conference was to sense the pulse of leadership in industrial design. The two-day summit provided a platform for the attendees to explore and analyse real-life challenges pertaining to industrial design. Divided into 10 interconnected sessions covering every aspect of industrial design, the event was highly interactive. Over 150 participants from across the industry, academia and professionals attended the event.

INAUGURAL SESSION During the welcome address at the inaugural session, Udayant

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Malhoutra, Chairman, CII National Committee on Design, and CEO & MD, Dynamatic Technologies, said, “Design is of strategic importance for the competitive growth of the nation and the whole world, since every initiative starts with design. The government, industry, academia and society have a vital role to play towards the development of design in the ecosystem.” Prof Pradyumna Vyas, Director, NID, delivered the theme address on ‘New Product Development’ wherein he expressed his views on the promotional attributes that contribute to design development. “In a globalised economy, India design mark needs to be incorporated among the industry as a symbol of good design practice,” he added. Furthermore, he stressed on design education that requires to be introduced as a curriculum in schools for creating the next generation design. While concluding the inaugural session, Professor G G Ray, HOD, Industrial Design Centre–IIT, Bombay, highlighted the necessity for formulation of design in a contextual manner, so that it can reach the lower strata of society. “In India, 60-65 per cent of the population is unaware of the significance of design, and hence, it is pivotal to sensitise about design advantage in a sequential and interactive way,” he noted.

DESIGN AND STRATEGY The sessions on day one focussed on design and strategy, benefits of collaboration between industrial and engineering designers, and the need for involving consumers in product development process. It

LEADERSHIP THROUGH INDUSTRIAL DESIGN

also identified new areas of consumer growth. Speaking about how design can help formulate a company’s strategy, Anil Sondur, VP, Tata Elxsi, opined, “Design drives product outcomes, positioning and differentiation, all within disparate cultural contexts and universal market forces.”

COLLABORATION BETWEEN INDUSTRIAL AND ENGINEERING DESIGNERS During the discussion on collaboration between industrial and engineering designers, Harshwardhan Gupta, Director, Neubauplan Machine Design Studio, and Pankaj Jhunja, Head, Design Quality and Realisation & Product Planning–India, Renault Nissan Technology & Business Centre, noted that as distinct professionals working in the field of new product development, it is essential for both categories of designers to collaborate and create. Often their distinct roles are confused. In such a situation, it is important for the company to create an environment conducive for collaborative work. Gupta says, “In terms of the interaction between industrial and engineering designers, it has

been noted that without managed collaboration, the direction of work can diverge with task fragmentation and reduced efficiency.” The first day witnessed many sessions by renowned speakers and culminated with the address of Prof Uday A Athavankar, Ramakrishna Bajaj Chair Professor & Emeritus Fellow Industrial Design Centre (IDC), IIT-Bombay. He explained about new techniques to uncover previously unexplored territory of industrial design.

varies from person to person. It is dependent on a variety of issues. Brand exists with people who have no experience. To build a brand with them will be a great experience.” Furthermore, Dipendra Baoni, MD, Lemon Design, added, “Brands are stories that evoke emotions and make people believe in them.” The other sessions included, ‘New and Unique Packaging’, ‘Aligning Industrial Design and Market Strategy’ and ‘Green Design’.

RESEARCH AND DESIGN

IN A NUTSHELL

The second day started with a session on ‘Insight Translation: Bridging the gap between research and design’. While speaking on the occasion, Manoj Kothari, Director & Principal Strategist, Onio Design, said, “Detailed market research is important for good design as it will give multiple justifications.” However, Satyajit Vetoskar, Head-Design, VIP Industries, averred, “Although research is not a bad thing, often people get stuck with the research results and ignore the reality.” While addressing a session on brand strategy, Sudhir Sharma, CEO, Indi Design, stated, “Brand is more of a perception. It

Right from the initial stages in the design process, perceived design opportunities are transformed through the generation of ideas and iterations, market research, problem definitions, collaborative coordination and potential design solutions. Teams establish what a design project should consist of, and whether it should exist at all, in a set of recommendations for a plan of action to present to the client. The event took the participants through every stage of the design process from concept to prototype, explaining the importance of each stage to arrive at an innovative product.

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ARC 8TH INDIA FORUM

LEVERAGING AUTOMATION TO DRIVE BUSINESS EXCELLENCE With India expected to become a fiercely competitive market, only those companies willing to pursue the goal of achieving sustainable competitiveness will emerge ultimate winners. Besides, there is a need to leverage technology for reducing operational expenses, achieving supply chain efficiencies and enhancing productivity. ARC Advisory Group’s 8th India Forum highlighted all the emerging trends and identified the scope of automation solutions in making companies globally competitive. A report…

Rajabahadur Arcot, VP & GM - South Asia & South-East Asia - Operations, ARC Advisory Group, lighting the inaugural lamp

anufacturers today can achieve sustainable and global competitiveness when they aim for excellence during the entire project lifecycle: project design & engineering, operations and maintenance. Only those companies that are efficient and cost-competitive will be able to maximise production capacity utilisation. While industrial facilities are highly capital-intensive, they are built to operate over many decades. Thus, maintaining and managing these assets throughout the plant lifecycle plays an important role in realising the returns. Also, the role of asset management systems has to be recognised. Addressing some of these needs of the process industry, ARC 8th India Forum highlighted the importance of automation in improving efficiency and productivity.

THE AGENDA ARC Advisory Group’s 8th India Forum

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‘Achieving Business Excellence Through IT and Automation Solutions’ was held recently in Hyderabad. The event, which has acquired a unique networking platform status for technological solution providers and end-users, was divided into two sessions. The first chapter was on the electric power sector and the second on process & batch industry. “ARC has structured the forum to help electric power companies and manufacturing firms in process & batch industry to drive innovation, sustainability and performance through the adoption of automation, enterprise and collaborative manufacturing systems and solutions,” explained Rajabahadur V Arcot, VP & GM South Asia & South-East Asia Operations, ARC Advisory Group. While the electric power industry track discussed the challenges and solutions related to generation, transmission and distribution companies, the process & batch industry forum included three distinct tracks on chemical and oil & gas; cement, metals,

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and pulp & paper; and pharmaceuticals, biotech and food & beverage industries. Additionally, the general sessions were devoted to asset management, sustainable manufacturing and industry standards. Thought leaders and decision-makers from ARC, end-user representatives from various process industry verticals, technology solution providers and others shared their experiences and thoughts through presentations, panel discussions & workshops. The forum’s focus was on maximising productivity through investments in automation and IT solutions, such as enterprise solutions, asset lifecycle management, collaborative production management systems, sustainability efforts, etc. Around seventy speakers shared their views about winning strategies and best practices that help manufacturers achieve business transformation needed to pursue business excellence. They discussed various aspects of automation and IT solutions, concepts and trends.

ARC 8TH INDIA FORUM

PROCESS & BATCH INDUSTRY In a roundtable discussion, a panel comprising AV Rao, VP Projects, ITC; A Narendra, Principal Consultant, Performix; Shivam Mittal, Director - Supply Chain, SAP; Ajay Kumar Dhir, Group CIO, JSL; and Arcot, highlighted the need of shop floor and enterprise process synchronisation. The panelists explained the importance of integration for seamless transfer of data between shop floor and enterprise. In addition, they emphasised on the need for return on investments (RoI), training, transparency, traceability, etc, while integrating the business processes. Speakers presented case studies on automation and information technologies specific to the manufacturing industry verticals, addressing their core challenges from a strategic perspective. The specific industry tracks on chemicals and oil & gas (including refining and petrochemicals) was chaired by R Rajamani, former MD, Mangalore Refinery & Petrochemicals (MRPL). The pharmaceuticals and food & beverages session was led by Shyam Bang, Executive Director, Jubilant Organosys; while that on cement, pulp & paper and metals & mining was chaired by Dhir.

AUTOMATION SOLUTIONS Rajamani briefed the audience about the various types of automation solutions to boost efficiency and improve safety standards of refineries. In his presentation, Dr Haibin Yu, President Assistant and Director - Overseas Business, SUCON, highlighted the usage of industrial automation solutions in the development of low carbon economy. Jasbir Singh, VP (E&I), Essar Projects, explained the benefits of Fieldbus applications over the conventional system. According to him, Fieldbus control system offers benefits like increased process efficiency & product quality, RoI, cost-effectiveness, and therefore, enhanced profitability, etc. The session was concluded with a presentation by SR Venkatapathy, Head - Research India & Senior Analyst, ARC Advisory Group, who highlighted the importance of safety standards in the process industry.

CONCLUDING REMARKS The deliberations on the last day were focussed on various industrial standards, such as benefits of adopting ISA 95 frameworks, ISA 100 and Wireless Hart, standardisation of Fieldbus followed by the session on activities and deliverables of Manufacturing Enterprise Solutions Association (MESA). The forum concluded with a panel discussion on the roadmap for meeting the countryâ&#x20AC;&#x2122;s need for skilled human resources. Training, interfacing with academia, preparing students for the future, and capturing the knowledge of the experienced workforce were some of the options suggested by the members. The factors like networking with thought leaders and learning from their experiences, charting the roadmap for technology adoption and tracking business and technology trends attracted over 400 delegates to the ARC Forum. The forum provided a unique platform for both technology suppliers and manufacturing companies to meet and deliberate on building a mutually rewarding relationship. And, ARC Advisory Groupâ&#x20AC;&#x2122;s 8th India Forum seems to have served that purpose well.

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AMTEX 2010

TAPPING GLOBAL OPPORTUNITIES The 7th edition of Indiamart AMTEX 2010, held in Delhi, was a grand affair, with representations from the who’s who of the machining and tooling world. With record international participation, the event proved to be the hub for innovative products, latest trends and manufacturing solutions. Promoted by Triune Exhibitors with SEARCH as the media partner, the event presented a great opportunity for interaction among manufacturers, suppliers and users. A report… Lighting of the lamp by the Guests of Honour. (L-R): Dr H P Kumar, Chairman & MD, National Small Industries Corporation, Oscar Fernandes, Hon’ble Member of Parliament, Rajya Sabha, and Bykere Nagesh, Additional Special Representative of Karnataka State

HEMA YADAV

he sprawling acre of Pragati Maidan, New Delhi, was home to the 7th edition of the Indiamart AMTEX exhibition. The event, over the years, has strengthened its position as one of the largest shows of machine tools, machinery and manufacturing technologies in the Asian region.

GLORIOUS LEGACY Indiamart AMTEX is the leading trade fair of the sector, presenting a wide and in-depth range of products and services across manufacturing verticals, from metal cutting and forming technologies, to precision tools, allied technologies and industrial automation. AMTEX, which came into being 10 years ago, has been sponsored by Indiamart since the past seven years. Over these years, the exposition has successfully achieved more than 300 per cent growth.

EVENT FOCUS ‘Innovation’ and ‘technology’ were the focus at this year’s event. Increased productivity and output, zero-error quality and improved flexibility at lower costs were some of the crucial factors in business that the exhibition addressed, while providing turnkey solutions for the industry. The exhibition was inaugurated by Oscar Fernandes, Hon’ble Member of Parliament, Rajya Sabha, who professed great hope for the industry, “Events like these provide great opportunities to

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manufacturers, as well as users. As participation for this year has been global, it provides a chance for our manufacturers to explore international competition, as well as for the global manufacturers to see how far India has progressed and what it has achieved.” Sharing his enthusiasm and hope was Guest of Honour Dr H P Kumar, Chairman & MD, National Small Industries Corporation, “Events like Indiamart AMTEX 2010 are useful for the industry, especially the small-scale vendors. The main focus here is on innovation, which is important in today’s scenario.” Among the main attractions at the exhibition, great buzz was for the China and Taiwan pavilions, which represented their machine tools industry. With the Indian industry opening up to new markets for collaboration and partnerships, the event helped local manufacturers promote their products in a globally competitive market. Another Guest of Honour, Bykere Nagesh, Additional Special Representative of Karnataka State (with the status of Minister of State), said, “The biggest advantage of this event is that it is being held in the capital. This encourages foreign participation and creates new avenues to explore.”

KEY EXHIBITS The Indian machine tool industry was represented by players like Dozco India, DMG MORI SEIKI India, Lakshmi Machine Works, Magal LVD India, etc. Various products like Wedge mount from

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Dynemech Systems, CNC turret punch press from Meiban Engineering Technologies, mould cleaning machine by Synco Industries were launched during the show. The enthusiasm and optimism among the exhibitors was palpable. “Events like these provide a platform for the industry to showcase their machines and check out competition effectively,” said exhibitor SK Saha, GM – Marketing, Electropneumatics & Hydraulics. The technology depicted at Indiamart AMTEX 2010 was much appreciated by the visitors of the event. Satish Kumar J, Senior Executive – Vendor Development, GEA Westfalia Separator India, said, “AMTEX is one of the best platforms to keep oneself abreast of what’s happening in the industry. Our company is looking for new investments in the coming year and the event has provided first-hand interaction with various manufacturers, which helps us in making decisions.”

GLOBAL PLATFORM This year the event catered to a worldwide audience with representations from various countries including Germany, Italy, Switzerland, Czechoslovakia, the US, Sweden, Belgium, Spain, Israel, Turkey, Japan, China, Korea, Malaysia, Sri Lanka and Singapore. Taking its success of the past several years to the next level, Indiamart AMTEX 2010 offered immense opportunities for the growing Indian and international markets.

INSTRUMENTATION & CONTROL 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 226 to find it quickly

PROCESS DENSITY MEASURING SENSORS

MULTI-CHANNEL SPECTROMETERS

entec GmbH manufactures Rhotec process density measuring sensors that enable highly accurate and continuous measurement of density up to 5 decimal places. It is possible to determine the concentration in w/w, V/ V, Plato, Brix, percentage extract and other density calculable scales. Measurement is based on the change in the frequency of oscillation as the solutions density changes while passing through a U-shaped tube. It is possible to measure the density of fluids containing dissolved and undissolved components of both organic and inorganic nature. The sensors operate over a wide temperature range. These also find application in various types of industries, such as alcohol measurement, brewery, liquid raw materials, entrance quality control, concentration adjustment of chemical in storage tanks during production, quality control of products before shipment, filling stations of chemicals, semiconductor industries, aluminium rolling mill, offset printing plates manufacturing, effluent-treatments and numerous other applications.

Rane Rao Reshamia Laboratories Pvt Ltd, Navi Mumbai 400 705. Tel: 022-2768 3175, Fax: 022-2783 4814 Email: rrrlabs@rrrlabs.com, Website: www.rrrlabs.com

PROXIMITY SENSORS utonics Corporation offers long sensing PRD series proximity sensors. These sensors are available in both shielded (flush) and non-shielded (non-flush) types. They also come in M12, M18 and M30 sizes with double the sensing distance than their conventional size sensors. The sensing distances like shielded and non-shielded are as follows, M12 with 4 mm & 8 mm, M18 with 7 mm & 14 mm; and M30 with 15 mm & 25 mm sensing. The proximity sensors are available in cable type (2 meter) and cable outgoing connector type. These sensors offer reverse polarity, over current and surge protection circuit. Basically the proximity sensors are available in DC 3-wire type, with operating voltage of 10-30 V DC. The long sensing proximity sensors series offers NPN or PNP output and NO or NC options and operation status indicator. These IP-67 waterproof structure and CE certified long sensing proximity sensors are very economical with high quality.

Autonics Automation India Pvt Ltd, Navi Mumbai 400 705. Tel: 022-2781 4305, Fax: 022-2781 4518 Email: india@autonics.com Website: www.autonics.com

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arl Zeiss India offers multi-channel spectrometers (MCS FLEX PDA 190-1015 mm & MCS FLEX CCD 190-980 mm) with built-in flexibility. Obstacles can be avoided or eliminated, provided one has the flexibility to act. The new housing structure of the MCS FLEX now allows much more flexible integration of the spectrometer module into usersâ&#x20AC;&#x2122; measuring systems and overcomes all obstacles. The MCS FLEX employs an imaging grating, an optical input and a CCD or PDA sensor array. The core of the spectrometer is a blazed flat-field grating for light dispersion and imaging. All the optical components are mounted in a housing made of a special alloy. The spectrometer modules can be integrated close to the process and are extremely versatile. Their applications range from thickness measurements of thin layers and chemical analyses to the characterisation of light sources and deployment as HPLC detectors.

Carl Zeiss India Pvt Ltd, Bengaluru 560 022. Tel: 080-2557 8888, Fax: 080-2557 9999, Mob: 09986414945 Email: info@zeiss.co.in, Website: www.zeiss.co.in

DIGITAL PANEL METERS inyMaster series true RMS and digital industrial panel meters from Elecon Measurements are manufactured with latest manufacturing technology & touchproof voltage and current terminals. All the models in this series have RS485 or RS232 MODBUS communication. Salient features include: simultaneous display of 4 instantaneous parameters; user-programmable Star/Delta/singlephase; VA selection scalar/vector/vector harmonic power factor compatible with RMS measurement or average sensing; auto scrolling & auto scaling; higher security protection with user-programmable password; higher CT/PT ratio programmability; current primary up to 99 kA & voltage primary up to 999 kV; measure 4-quadrant power & energy optional; generator RPM display; voltage & current phase angles; neutral current display; active energy, positive energy accumulation, reverse lock; OLD register to store last reset energy; and load hours.

Elecon Measurements Pvt Ltd, Bengaluru 560 064. Tel: 080-2846 1777, Fax: 080-4127 2461 Email: contactblr@elmeasure.com, Website: www.elmeasure.com

DIGITAL PRESET TIMERS abrotech offers digital preset timers (model FC2541 & FC2561) that are useful for time and control application in various industries. These 4-/6-digit timers can be used in different combination of hour, min and second covering the time range from 0.1 second to 9999 or 999999 hour with the help of dip switches. They can be reset by front switch or from rear terminal. The up/down counting or cyclic mode can be selected through dip switches. Cyclic mode can have equal on/off time or unequal off+on time set by 2+2 (4digit) & 3+3 (6-digit) thumbwheel switches. Bright red 7-segment 4/6 nos of 0.56-inch height LEDs, display the time. Output is

INSTRUMENTATION & CONTROL

provided through 1 or 2 NO/NC relay contacts rated at 5 A/230 V. Operating supply voltage is 230 V AC + 10 per cent, 50 Hz. The digital preset timers are housed in enclosures of DIN size 96 mm (H) x 96 mm (W) x 110 mm (D). Fabrotech, Mumbai 400 072. Tel: 022-2847 4820, Fax: 022-2852 0621 Email: fabrotech@samdani.com

DIGITAL VIBRATION METERS P Systems offers digital vibration meters that are specially designed for easy onsite vibration measurement of all rotating machinery for quality control, commissioning and predictive maintenance purposes. These vibration meters have high quality accelerometers for accurate and repeatable measurements. They have a wide frequency range of 10 Hz to 10 kHz in acceleration mode. Salient features include: bearing condition monitoring function; LCD digital display; lightweight and easy-to-use; automatic power shutoff to conserve power; AC output socket for headphones recording; and optional software & cable for RS232C interface. Some of the technical specifications are: display of 4-digit, 18 mm LCD; piezoelectric accelerometer transducer; measuring parameter of velocity, acceleration & displacement; and multi-functional type RPM & frequency, besides parameters measured by the standard type.

G P Systems, Meerut 250 001. Tel: 0121-251 0115, Mob: 09358805107 Email: info@gpsystems.in

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INSTRUMENTATION & CONTROL

WELDING GAUGES ridgeCam welding gauges offered by India Tools & Instruments Co are simple to use all-in-one gauges. These welding gauges are used for measuring weld: undercut, excess material, fillets, weld size & height, preparation angle and misalignment. Measurements such as angle of preparation, 0-degree to 60-degrees; excess weld metal (capping size); depth of undercut; depth of pitting; fillet weld throat size; fillet weld length; and misalignment (high-low) are possible either in inches or millimeters.

India Tools & Instruments Co, Mumbai 400 003. Tel: 022-2342 8862, Fax: 022-2341 2578, Mob: 09819345050 Email: itico@vsnl.com, Website: www.indaitools.net

PROCESS TRANSMITTERS ibratherm Intruments offers microcontroller-based process transmitters (model PTX-3000) for measuring and transmitting the analogue and digital values proportional to the process input. Three options are available, where users can specify the desired model for universal input or any of the two fixed inputs or any of the single fixed inputs. Temperature or process values corresponding to the input is indicated on the display and the corresponding display range is converted to the 2-wire isolated current output of 4-20 mA

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INSTRUMENTATION & CONTROL

proportional and linearised to the process input. This linearised signal can be used for remote measurement and indication. For the dual input model PTX-3000/T, two independent 4-20 mA signals are available on three wires. For interface with PLC or DCS or with any other process controller, the measured and displayed analogue input is converted for digital serial communication on RS485 bus with MODBUS RTU protocol in slave mode. Libratherm Instruments, Mumbai 400 068. Tel: 022-2896 3823, Fax: 022-2896 0569, Mob: 09821136685 Email: libratherm@libratherm.com, Website: www.libratherm.com

TEMPERATURE CONTROLLERS EEC-make hot runner temperature controllers offered by PBJ Industrial Electronics continue to gain popularity in injection moulding. The main advantages are speed and yield, reducing cycle times, achieving better part quality, generating less scrap and no material waste from the sprue and runner system. Key parameters that make up good temperature controls are: temperature measurement: the best results require measurements to be fast, accurate and free of any noise component; output power calculation: the best results require the parameter values used in the control algorithm to match the process time constants to each zone; and delivery of the output power: the best results require the best resolution of the output power over the shortest time period. One of the fundamental criteria of the hot runner temperature is controlling the temperature as accurately and consistently as possible with respect to the required process setpoint.

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INSTRUMENTATION & CONTROL

PBJ Industrial Electronics Pvt Ltd, Mumbai 400 067. Tel: 022-2868 2283, Fax: 022-2868 3460 Email: info@ieecpbj.com, Website: www.ieecpbj.com

SUPER-THERMOMETERS TL Technologies offers Fluke 1594A and 1595A superthermometers from Hart Scientific, that combines the accuracy of complex and expensive bridges with innovative features, which simplify measurement processes and provide excellent value. Both the super-thermometers are perfectly suited for calibrating SPRTs, PRTs, and thermistors. They are accurate enough for the primary lab and economical enough for the secondary lab. The measurement accuracy of the 1595A over typical thermometry ratios (0.25 to 4.0) is as good as or better than 0.2 ppm. And for ratios near unity (0.95 to 1.05), the resistance ratio accuracy of the 1595A is as good as 0.06 ppm. New patent-pending design innovations incorporated into the super-thermometers reduce measurement noise and interference to levels that are unprecedented for a digital thermometry bridge. In a typical temperature calibration application, the super-thermometers offer uncertainty due to measurement noise as low as 0.00002째C.

TTL Technologies Pvt Ltd, Bengaluru 560 008. Tel: 080-2525 1859, Fax: 080-2529 1285 Email: rashmi.sreedharan@ttlindia.com Website: www.ttlindia.com

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PUMPS

CHEMICAL PROCESS PUMPS Bole & Co offers chemical process pumps for a wide range of applications in chemical, petrochemical, pharmaceutical industries, fertilizers, oil refineries, paper mills, sugar mills, dairy, pesticides, etc. These pumps are available in various types, such as centrifugal, self-priming, vertical sump and monoblock. Materials of construction of the pumps are polypropylene, SS-316, CS and CI. The pumps are incorporated with special mechanical seal or gland packing to suit individual requirement depending on the nature of the liquid to be handled.

C Bole & Co, Mumbai 400 003. Tel: 022-2342 4350, Fax: 022-2342 4040 Email: response@cboleco.com, Website: www.cboleco.com

ROTARY GEAR PUMPS ositive displacement rotary gear pumps (type DW) manufactured and offered by D I Engineers are available in 10 sizes ranging from ½” to 6” in 30 different capacity ranges, from 0.5 to 200 m³/hr, and in four different versions. Foot-mounted horizontal inlet outlet flange conform to BS-10 table H or ASA-150, B16.5 with in-built safe relief valve. These pumps are suitable for fuel pressuring & transfer application, lubrication system fuel oil loading/unloading, etc. Maximum working pressure is up to 35 bar. The positive displacement rotary gear pumps are available with ball bearings, bush bearings and needle roller bearings.

D I Engineers, Dist Surendranagar 363 035. Tel: 02752-240173, Fax: 02752-240925, Mob: 09426421242 Email: roparpumps@rediffmail.com Website: www.roparpumpsindia.com

ROTRAY VANE VACUUM PUMPS irect drive rotary vane vacuum pumps (TRP series) from Indo Woosung Vacuum Co are double-state pumps available in the capacity of 80 LPM to 1250 LPM with ultimate pressure of <5 x 10-4 torr. These vacuum pumps have in-built advanced design pump isolation and anti-suck back valve mechanism. The cartridge-type design enables easy serviceability. Features include: constant pressure oil circulation system; anti-corrosive materials; three position gas ballast valve; lightweight aluminium construction; high degree of vacuum with low power consumption; specially developed vane material with very low coefficient of friction; and very low noise & vibration levels with low vacuum oil charge.

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PUMPS

Indo Woosung Vacuum Co Pvt Ltd, Mumbai 400 080. Tel: 022-2561 3336, Fax: 022-2561 3335, Mob: 09324280001 Email: iwvcplm@mtnl.net.in, Website: www.indowoosung.com

PLUNGER METERING & DOSING PUMPS implex plunger metering and dosing pumps manufactured by Jagdish Engineering Works are simple and easy-to-operate. All parts are in these pumps are interchangeable and readily available. Simplex displacement metering and dosing pumps have the capacity of 2 to 10000 LPH and working pressure up to 200 kg/cm². Flow rate of the liquid can be adjusted by controlling stroke length of the pump when the pumps are in operation or in stationary mode. Materials of construction can be provided in CI, MS, SS304, SS316, alloy-20, hastalloy B, C, or as per clients’ requirements. Duplex plungeroperated metering pumps have the capacity of 2 to 10000 LPH per single head, therefore a total of 5000 LPH, and pressure up to 7 kg/cm² is obtained. Single gearbox and motor with tow pump heads on common baseplate are provided. These pumps are mainly used for blending of two liquids in required ratio hence both the pump heads can be individually adjusted.

Jagdish Engineering Works, Mumbai 400 063. Tel: 022-2685 3584, Fax: 022-2873 5555 Email: jew@jewpump.com, Website: www.jewpump.com

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PUMPS

ROTARY VANE LOW VACUUM PUMPS inivac SVL series of low vacuum pumps offered by Shree Siddhivinayak Industries are sliding rotary vane-type direct/ belt-driven vacuum pumps mounted on common base frames. These vacuum pumps are compact in size, vibration-free and hence can be mounted inside the machines. They attain maximum vacuum levels up to 29” Hg and their capacities range from 50 LPM to 2000 LPM. The unique design of lubrication system positively feeds minimum required oil to all rotating and frictional parts. Oil-free versions are available with a maximum capacity of 1500 LPM. These dry-type pumps require no internal lubrication and have vanes of prime quality impregnated graphite. Monobloc models are available up to 150 LPM capacity and a maximum vacuum of 25” Hg. The rotary vane-type low vacuum pumps are useful in many applications, like capsule filling/ capsule printing machines and other pharmaceutical machineries, packaging/labelling machines, screen printing/plate making, book binding/folding machines, vacuum chucking, etc.

Shree Siddhivinayak Industries, Dist Thane 401 104. Tel: 022-2845 8372, Fax: 022-2845 7073 Email: minivac@rediffmail.com, Website: www.minivacpumps.com

PISTON VALVES B Panchal & Company offers seatless and glandless piston valves that are available up to 4” size and do not have any stuffing box. The piston slides between the two packing rings made of asbestos PTFE and do not rotate, hence there is

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minimum ware. Bottom ring rests on a cast machined groove of the body and upper packing ring is being held and remained pressed by a bonnet on top. The bonnet rests on the top ring, when tightened evenly by the nut of the stud presses the lantern bush which in turn presses the bottom ring. When any leakage is observed from the hole of the bonnet, it can be stopped on the line. The valves find best application in control of steam and thermic fluid line. They also have numerous applications in the control of liquids and gases. A B Panchal & Company, Ahmedabad 380 004. Tel: 079-2562 0629, Fax: 079-2562 1027 Email: sales@abpcovalves.com, Website: www.abpcovalves.com

PULP VALVES nife edged pulp valves manufactured by Flochek Industries are robust in design, slim and lightweight having compact features. These valves are available in cast iron (FG-200), cast carbon steel (216/WCB) and stainless steel (AISI-304) with rising stem of 13 per cent cr steel, plate (gate) of SS-304. Lower scour plate is provided for cleaning purpose. Wafer ends are suitable for mounting between flanges to ASA/BS/IS/PN standards. The pulp valves are ideally suited for use in paper and sugar mills. They are available in sizes ranging from 50 mm to 400 mm NB.

Flochek Industries, Kolkata 700 001. Tel: 033-2242 9704, Fax: 033-2243 3173, Mob: 09830293499 Email: flochek@satyam.net.in, Website: www.flochekvalves.com

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BUTTERFLY VALVES ndo German Shell Cast offers butterfly valves that are manufactured from SS-316/SS316L bar stock. These valves can be welded, screwed, clamped or flange-fitted. They can be dismantled and assembled without tools and in minutes. The butterfly valves can be cleaned and steam sterilised. End connections can be SMS, DIN, TC clamp, butt-weld and flanged.

Indo German Shell Cast, Mumbai 400 104. Tel: 022-2676 3662, Fax: 022-2676 4011 Email: igsc1967@rediffmail.com, Website: www.igscindia.com

DIAPHRAGM VALVES D K Engineering Industries manufactures and offers diaphragm valves that are mainly used in water treatment plants, fertilizer & petrochemicals industries, chemical industries, refineries, thermal power stations, and other process industries. Equally suited to on & off, or flow control applications, the diaphragm valves handle positive pressures or high vacuum. Due to the wide range of material options these valves can handle almost all applications within their temperature and pressure ranges (175째C max & 16 bar max) and as such are used in almost every industry on both corrosive and abrasive applications. All working parts are isolated from the line media, which enhances their reliability. Maintenance is a simple task

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with the body remaining in the pipe, the valves thus being field serviceable. The diaphragm valves have linear flow characteristics, which makes them well suited to throttling or modulating duties. B D K Engineering Industries Ltd, Hubli 580 030. Tel: 0836-2331499, Fax: 0836-2330799 Email: bdkho@bdkindia.com, Website: www.bdkindia.com

QUARTER TURN VALVES i-Fab Valve Automation, in technical tie-up with BAR GmbH, Germany, offers customised and innovative solutions for automation of ball valves, butterfly valves and plug valves. The product range includes quarter turn valves fitted with: pneumatic actuators, electric actuators, and accessories. The pneumatic actuators have double-acting & spring return actuators to handle torques up to 12000 Nm and 4000 Nm respectively. These are guaranteed for 1 million cycles. They have swing angles of 90, 120 & 180degrees, with 3-position operations of 0-90-degrees-180-degrees & 045-degrees-90-degrees; and chemical version for corrosive environments. Electrical actuators are for torques up to 300 Nm. These are available in fail-safe and position control versions. Accessories include: solenoid valves (NAMUR), limit switch boxes, electro-pneumatic valve positioners, and manual override.

Hi-Fab Valve Automation, Mumbai 400101. Tel: 022-4076 6555, Fax: 022-4076 6556 Email: valves@hi-fab.com, Website: www.hi-fab.com

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PNEUMATIC CONTROL VALVES

rightech Valves & Controls offers Accu-Flow series 77 globe-type, single-seated, top-guided, single-spring & diaphragm actuated, throttling/on-off type pneumatic control valves. These are top-guided single-seated control valves that provide maximum support to ensure plug stability. Quick-change trim is provided as standard construction for easy maintenance as the valves are gasketed into the valve body. Stellited trims are provided for high pressure and temperature service. Class IV leakage is standard and optionally soft seating is provided for class VI leakage. Size ranges from 15 mm to 500 mm. Pressure rating is up to class 600.

Brightech Valves & Controls Pvt Ltd, Ahmedabad 382 430. Tel: 079-2290 2911, Fax: 079-2297 3500 Email: info@brightechvalves.com, Website: www.brightechvalves.com

SOLENOID VALVES adho Controls manufactures and offers 2/2-way directacting pilot-operated heavy-duty solenoid valves for on/off applications to control steam, water, air, gas at line pressure up to 10 kg/cm² and temperature of 140°C. Size of these valves ranges from ½” to 2” BSP/NPT with 2-way gun metal body. These vertical mounted solenoid valves have heavy-duty H-class insulation coil with tight shutoff. The solenoid valves are used in boiler industry, furnace to control oil, air, etc.

Madho Controls Pvt Ltd, Thane (W) 400 606. Tel: 022-2588 3252, Fax: 022-2588 3252, Mob: 09820066046 Email: madho@vsnl.com, Website: www.madhocontrols.com

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OIL-WATER SEPARATORS he Öwamat oil-water separators for disperse compressor condensates are field-proven branded products that are continuously enhanced and adapted to the latest state-of-theart. These units, which are ready for connection, have so far been available in 4 sizes (2, 4, 6 & 8). The latest addition (Öwamat-1) has a height of only 52 cm and is therefore the smallest device in this range. It is designed for compressors with a performance up to 1, 4 m³/min. The Öwamat oil-water separators are supplied with means for floor wall-mounting. Due to their small size, these devices can easily be integrated into existing systems or even incorporated into the compressor housing. The units are provided with two condensate inlet points and can be turned into wall mounting. Compact design of the Öwamat-1 device includes Beko´s well-known, robust pressure-relief chamber and effective filter technique.

Beko Compressed Air Technologies Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 0275, Fax: 040-2308 0274, Mob: 09393002464 Email: rkreddy@bekoindia.com, Website: www.beko.de

COVER BLOCKS ightvision presents with a worldclass plastic product known as cover block used in place of concrete cover block (in RCC construction). These blocks not only help to keep the reinforcement bars at the specified place, they also offer convenience of use. The cover blocks are available in various sizes, and avoid time consuming procedure of casting plain cement concrete cover blocks. Size of cover blocks is always accurate as the blocks are made in a factory where moulds have already been designed with higher accuracy and the final HDPE blocks are made in injection moulding machines. In comparison to conventional-type, strength of HDPE cover blocks is much higher and they hardly get broken inside cement concrete during placing of heavy steel shutters or during use of heavy vibrators. Moreover, since cover blocks are manufactured in injection molding machine the accuracy is always higher than conventional-type of cover blocks.

Rightvision (India) Pvt Ltd, Noida 201 303. Tel: 0120-4261026, Fax: 0120-4261026, Mob: 09810526627 Email: rightvision@rightvision.biz, Website: www.rightvision.biz

BENCH DRILL PRESSES itachi Koki India offers bench drill presses (model B-16RM) that are equipped with laser guide. The bench drill has a chuck capacity of 16 mm and 12-stage speed of 210-2580 RPM for drilling in various materials, like mild steel, aluminum, etc. Salient feautres are: durable cast iron table where surface tilts of 45-degrees (left & right) is possible; laser guide X/ Y projection lines for realignment of drilling location, ensures top class accuracy; depth adjustment gauge for accurate drilling of repetitive depth holes; built-in light; and quick belt tension release knob for fast speed setting. Technical specifications include: power input 750 W, swing 380 mm, spindle travel 85 mm, table size 336 mm x 336 mm, overall height 1618 mm, and weight 75 kgs.

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Hitachi Koki India Ltd, Bengaluru 560 058. Tel: 080-4117 0777, Fax: 080-4117 1222, Mob: 09008304461 Email: ho@hitachi-koki.in, Website: www.hitachi-koki.in

HUMAN MACHINE INTERFACES ro-Face has announced its first release of the new compact human machine interface (GP4100 series) that caters to the industry needs and which is the best in its class (claims the company). The GP4100 series models are equipped with 3.4inch, 16-level gray scale and 200 x 80 pixels high-resolution display offering touch operation as well as high quality display capability of full graphic and text data with expanded support of Windows image and bitmap fonts. This series is supported with the new version of widely used editor software in the industry, GP-Pro EX version 2.6, which is freely downloadable from the Pro-face website. This also supports program transfer from the PC via the mini-B port without requirement of any special cable. Two types of 3-colour high-brightness LED backlight, green, orange and red or white, pink and red can provide operators with easy-to-see operation status from distance.

Pro-Face India, Bengaluru 560 066. Tel: 080-3066 7454, Fax: 080-4011 8025, Mob: 09845501988 Email: sales.proface@proface.co.in, Website: www.pro-face.co.in

CORE DRILLING UNITS ein presents two core drilling units for efficient and precise core drilling with a diameter of up to 80 millimeters: the Fein KBM 80 U with manual drive; and the Fein KBM 80 U auto with the first fully automatic, digitally controlled drill feed. These drilling units guarantee constant drilling times and save time and money on big drilling jobs. They also deliver increased works safety, as operators don’t have to manually intervene in the drilling process. The new Fein core drilling units cover all applications, such as core drilling, twist drilling, thread cutting, countersinking and reaming. They are used in metal & steel construction as well as in construction of bridges, machines, ship & containers; and in all other related metal industries. Key features include: cost–effective & precise core drilling; operating comfort & safety with Viseo Touch Pad; and powerful yet with optimum power-to-weight ratio.

Fein Power Tools India Pvt Ltd , Chennai 600 024. Tel: 044-4357 8680, Email: info@fein.in, Website: www.fein.in

CONNECTORS ummel AG, Germany has launched Twintus connectors for small drives. The miniaturisation pluggable solutions in the drive set the Twintus Hummel of new standards. It combines dynamic design and functionality in a single housing, and is extremely efficient, providing even the smallest servomotors a pluggable solution. In addition to running with two M16 connectors connections, the Twintus is also now available in the combination of M16 + M12 and follows a trend

NEW LAUNCHES

in engine development, while the M16 connector assumes the power transfer. It is used as a signal connector of the 8-pin M12 connector, an interface that has now established itself as the standard for digital encoders. Hummel Connector Systems Pvt Ltd, New Delhi 110 070. Tel: 011-2689 4005, Fax: 011-2689 4006, Mob: 09910405864 Email: v.kumar@hummel.com , Website: www.hummel.com

AUTO TRANSFER SYSTEMS rodaid Engineers have developed an arrangement for auto transfer of products to furnaces without manual intervention. This arrangement consists of receiving chute for the products, cleated elevating conveyor and product distribution to the furnace conveyor. The cleated elevator is made from lightweight Delrin slat chain with cleats and requires as small as Âź HP drive. The variable speed of 2-10 m/min for the chain is provided using VFD unit, which helps to vary the speed to match the machine output. This arrangement ensures auto transfer, and also ensures full utilisation of furnace capacity. The systems are ideally suitable and must for continuous operating equipment, such as conveyorised furnaces, ovens, product washing machines, etc.

Prodaid Engineers (P) Ltd, Bengaluru 560 058. Tel: 080-2837 4961, Fax: 080-2837 4961 Email: prodaid@vsnl.net, Website: www.prodaid.com

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SCREW AIR COMPRESSORS lobal series screw air compressors from Elgi Equipments are available in 11-22 kW power range. Featuring a compact footprint and producing a noise level of no more than 68±3 dBA, these air compressors are the most silent machines in the market (claims the company). The new direct drive compressors have a low operating speed, which makes for an extended life and less maintenance. They are fitted with Elgi’s energy-saving Flexair Axis airends, which have a unique screw profile and low specific power consumption. Control of the machines is through Elgi’s Neuron+, which facilitates remote monitoring and data analysis. The Neuron+ is integrated with a variable frequency drive (VFD) and a drier controller. The new family of compressors is designed to run at high temperatures, being fitted with highly efficient after-coolers. A moisture separator with an auto-drain facility is provided to drain condensed moisture. The compressors meet the world’s most stringent safety norms and are CE marked.

Elgi Equipments Ltd, Coimbatore 641 005. Tel: 0422-2589326, Fax: 0422-2573697, Mob: 09790039326 Email: enquiry@elgi.com, Website: www.elgi.com

RETRO-REFLECTIVE SWITCHES roximon Controls offers retro-reflective switches that consist of one device and a reflector. These devices contain emitter and receiver. The rays emitted by the emitter are reflected by

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the reflector to the receiver. Sensing of the object occurs when these rays are interrupted. Some of the advantages of these switches include: easy assembly compared to through beam type; and large active sensing range compared to diffused beam type. The retro-reflective sensors can be used where it is difficult to install through beam sensors due to space constraint. Further, simple wiring makes it suitable where sensing objects are bigger in size. Thus these sensors are used for loop control in decoiler, edge detection in paper/sheet metal, etc. Proximon Controls Pvt Ltd, Thane 400 606. Tel: 022-2588 9244, Fax: 022-2588 9246, Mob: 09820059434 Email: info@proximon.com, Website: www.proximon.com

SURFACE GRINDING MACHINES LB Schliff Werkzeugmaschinen offers used surface grinding machines. Some machines are refurbished at ELB Schliff Germany; and some machines are as and where is basis. A wide range of horizontal surface grinding machines are available with table stroke of 600, 800, 1000, 1500, 2000 mm. Table drive can be hydraulic, belt driven or ball-screw driven with servo motor. The table carries electromagnetic chuck to suit the table size. Wheel head

GENERAL PRODUCTS

is mounted with simple straight-line hand dresser or electrical straight-line dresser or form dresser. The grinding machines have control range with auto grinding cycle, auto cross traverse grinding cycle. Vertical Y-axis carrying digital display carrying feedback either from motor mounted rotary encoder or linear glass scale mounted on Y-axis slide. Different machine models with different types of table drives and different electrical control systems to suit various grinding applications are available to choose from. ELB Schliff Werkzeugmaschinen GmbH, India Office, Vadodara 390 021. Tel: 0265-239 8715, Fax: 0265-2398715 Email: nitin@elb-schliff.de

TUBE MILLS TL Industries manufactures and offers tube mills in many sizes to suit customers’ requirements from simple-manual type to sophisticated and automatic type based on technical know-how from German collaborators. These tube mills have flexibility, and are needed for producing pipes & tubes in different sizes and gauges. Design and composition of various sub-assemblies are made and supplied according to customers’ needs. The main purpose of the shear and welder is to feed the mill with coils uninterrupted. Roller changing facility is by removing front stand up to 4” sizes and from top for other sizes. Additional features like raising the top rollers simultaneously, adjustments of roll centers while running, cassettes for quick roll changing can be provided.

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A double tool type bead trimmer is provided to remove the extra weld metal on the pipe. Raising and lowering of tool is fully automatic strictly controlled by micro screw for tool adjustments. ITL Industries Ltd, Indore 452 015. Tel: 0731-3044400, Fax: 0731-2721110 Email: itlindia@sancharnet.in, Website: www.itl.co.in

LOAD TURNING DEVICES ureishi Enterprises offers Rotomax load turning devices, by means of which bulky goods can be turned over and rotated safely and trouble-free, without damage and without accidents. The material being turned can be stopped in any position. The capacity of the standard devices ranges from 1,000 kgs to 100,000 kgs. Special devices are available with lateral belt adjustment and automatic load compensation. PES bands with up to 20,000 kgs capacity can be used as load suspension gear. For all capacities beyond that, woven steel slings or chains are required. Magnetic edge protectors for sharp-edged parts are available as accessories. Suitability for use in mobile applications is another special advantage of the Rotomax. The load turning device is brought directly to the point of use, where the component to be rotated is then turned safely with any adequately sized crane. The turning operations can then be simulated with a CAD programme.

Qureishi Enterprises, Mumbai 400 050. Tel: 022-6785 9999, Fax: 022-2643 4462 Email: sales@slingset.com, Website: www.slingset.com

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SILICON GREEN SYNTHETIC QUENCH FLUID eneration Four Engitech, in technical collaboration with world renowned Source Explorer Ltd, Hong Kong, manufactures 4th generation, cost-effective silicon glow synthetic quenching fluid (Hitech Quench G22) which has very low kinematic viscosity: 22 cSt at 40째C; high flash point: 205째C (ASTMD-92); typical cooling rate 97 (c/s) at 607 (c) ASTM-D 6200; lowest pour point: -35째C; high boiling point: 351째C at 1013 mbar; negligible moisture content less than <90 part per million with sap value 0.50 mg KoH/g Nil ASTM D-94 provide high thermal and high oxidation stability. Distinct features include: eco-friendly & non-hazardous, gives it a long and low maintenance life resulting into low top ups, reduction in problems of low as well as high boilers. The Hitech Quench G22 is a 100 per cent synthetic fluid formulated to take care of several limitations attached to mineral thermic fluids. It is highly compatible with other quenching fluids.

Generation Four Engitech Ltd, Jodhpur 342 001. Tel: 0291-5107038, Mob: 09214048652 Email: en@hitechsolution.co.in

SERVO PLANETARY GEAR REDUCERS

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trategi Automation Solutions offers servo planetary gear reducers that are perfect solution for servomotor applications, such as packaging machines, gantries, injection moulding machines, pick-&-place and linear slides. These gear reducers are offered in concentric shaft, right angle solid shaft and right angle hollow shaft designs with modular adaptor flanges; and keyless compressible bushings to easily mount to any

GENERAL PRODUCTS

manufacturerâ&#x20AC;&#x2122;s servomotor. They can be chosen from standard backlash, low backlash and precision backlash. There are 5 basic sizes available as single and double reduction units. Input power ranges from 30 W to 5 kW. Input speed is up to 6,000 RPM. Ratio range is from 3:1 to 81:1. Nominal output torque ranges from 1.0 Nm to 108 Nm. Features include: case carburised & hard-cut helical gears, O-ring in piloted adaptor flange, grease lubrication, contact lip seals & sealed input shaft bearing, acculok keyless locking hub, oversised bearings, optional output flanges, etc. Strategi Automation Solutions Pvt Ltd, Bengaluru 560 048. Tel: 080-3248 9798, Fax: 080-4116 3047 Email: corporate@strategiautomation.com Website: www.strategiautomation.com

AUTOMATION DRIVES anfoss VLT automation drives (FC-300) offered by Air Fluid Engineers & Equipments is a single drive concept that covers the entire range of application, which is a major benefit in commissioning, operating and maintaining the equipment. The VLT automation drives offer an intelligent plug-&-play technology and unmatched reliability. These are extremely effective flexible and cost effective drives suitable for all industry applications, from simple speed control to dynamic servo application. They meet the requirements for enclosure class IP20/ chassis, optional IP21/NEMA 1, IP55/NEMA 12, IP 54/NEMA 12 or IP66 NEMA 4x. The VLT automation drives feature logic control functions and a sequence control based on events and actions. They come standard with the safe stop

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functionality suitable for category-3 installations according to EN 954-1. This feature prevents the drives from starting unintended. The logic control panel (LCP) can be plugged in/out during operation. Air Fluid Engineers & Equipments, Chandigarh 160 002. Tel: 0172-5012220, Fax: 0172-501 2221 Email: airfluid@airfluidindia.com, Website: www.airfluidindia.com

INDUSTRIAL Y-TYPE STRAINERS ngineers Combines manufactures and offers high quality industrial Y-type strainers that find applications in assortment of industries. These industrial strainers are used for separating little amounts of particles (solid). They are manufactured from premium quality raw materials. The strainers are easy to install and durable. They are available in different specifications and grades. Basket strainers can be obtained at cost-effective prices. Salient features include: strainer screens perforated + wire mesh (wire mesh available in 20/40/60/80 & 100 mesh); and screen materials: SS-304, SS-316, SS-304L, SS-316L, etc. Technical are: size ranging from ½” (15 mm) to 2” (50 mm) with threaded end of 1” (25 mm) to 12” (300 mm) & flanged end; class: 150#, 300# & 600#; and design: as manufacturing standard.

Engineers Combine , Ahmedabad 380 025. Tel: 079-3295 4584, Fax: 079-4003 5746, Mob: 09824068774 Email: mukesh@valveindia.com, Website: www.valveindia.com

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SHOT BLASTING MACHINES ec Shot Blasting Equipments manufactures and offers a wide range of door-mounted 30” to 120” diameters swingtable type shot blasting machines. These shot blasting machines have lightweight capacity of 500 kgs to heavy-weight capacity of 4500 kgs weight components, which are conventional, most economical low powered and commonly used machines by small, medium and large scale foundries, heavy machineries as well as various types of industries. To suit the requirements, different models are available with various accessories, like second door for additional productivity, either manganese or rubber linings on tables, doors & cabinet walls and either gravity type for low dust load or rotary screen type for screening of high sand & rust content dust generated along with fabric and pleated type bags dust collectors, which are operated by either mechanical shaker type or compressed air reverse pulse operated bags cleaning.

MEC Shot Blasting Equipments Pvt Ltd, Jodhpur 342 005. Tel: 0291-2740609, Fax: 0291-2742409 Email: mail@mecshot.com, Website: www.mecshot.com

TURBO-FLOW FILTERS autam Pneumatics manufactures and offers Airchamp turboflow filters that are available in 3-pipe sizes of ¼, 3/8, and ½ BSP. Filtration of compressed air removes water, oil, dirt and other

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contaminants, protecting air-driven equipments and instruments. These filters are exceptionally efficient in removing impurities with minimum pressure drop. They are based on baffle system of first moisture and impurities separation and then secondly filtering through the pure sintered bronze element. Maximum pressure is 250 psig. Maximum temperature is 50ยบC. The filters are available in polycarbonate transparent bowl of 230 ml capacity with easy operating manual drain cock. They are also available with metallic bowl guard. The filters are supplied standard with 25 micron element, 5 micron or 50 micron that are available on request. Also available are body pressure die cast zinc alloy/LM6, parts acetal, seal gaskets buna/ viton, etc. Gautam Pneumatics Pvt Ltd, Gurgaon 122 016. Tel: 0124-3092812, Fax: 011-2328 8888, Mob: 09313746944 Email: airchamp@vsnl.com, Website: www.airchamp.com

DOCK SHELTERS andhi Automations offers a complete range of dock shelters for every kind of use and environment, manufactured by Campisa Srl, Italy. These dock shelters protect the internal heated environments from the outside cold conditions, the chilled ones from outside heat, and all from rain, wind, snow, dust, etc.

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Retractable PVC front panels dock shelters are the most popular ones due to their simplicity, low cost and efficiency. These are available for dock level installation, or for ground level installation for the protection of doors without dock. Due to their high insulation factor, cushion dock shelters are ideal solution for controlled temperatures. Hydraulic dock shelters have standard or insulated perimeter panels that wait in open position the vehicle. These close only after the lorry has stopped in the final docking position, by a hydraulic mechanism tied with the dock leveller power source. Gandhi Automations Pvt Ltd, Mumbai 400 064. Tel: 022-6672 0200, Fax: 022-6672 0201 Email: sales@geapl.co.in, Website: www.geapl.co.in

GEAR OPERATORS wwa (India) Technologies offers turbo range of quarter turn and multi-turn gear operators. The gear operators are flawless in turning the valve disc from open to close position and viceversa by 90-degrees. Advantages are: easy installation & minimum maintenance; adaptability to suit either manual or motorised operation by means of simple

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modification; mounting flange on the gearbox is designed to suit ISO 5210 or DIN 3210 standard; and gearboxes are subject to extensive testing under extreme conditions ensuring that the gearbox is perfectly geared to meet the process environment. A pilot hole is provided on the hosing to enable easy fillings of lubricant. To increase the operating torque range a secondary unit is provided with spur gear attachments and accessories. The turbo valve operators are produced in strict adherence to a well-defined quality system to offer customers totally reliable products and values only customer satisfaction as their true. Awwa (India) Technologies, Bengaluru 560 091. Tel: 080-2836 0784, Fax: 080-2836 0784 Email: awwa_technologies@rediffmail.com

GRINDING BELTS harat Udyog offers Hermesit pure high-performance grinding belts manufactured by Hermes Abrasives Group, Germany. These long-life grinding belts have special hollow spheres covered with grain and produce typical Hermesit finish, called Hermesit bright effect. When grinding with Hermesit abrasives, the roughness depth of the surface of the ground workpiece is the same throughout the entire lifetime of a belt. When grinding with conventional abrasives, an even surface quality can be achieved for only a relatively short time. The abrasive grain becomes blunt and the desired initial roughness depth drops considerably.

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PERISTALTIC PUMPS iclins India offers a wide range of (PP series) peristaltic pumps with flow rates ranging between 0.1 ml/hr and 60 ltr/hr. These pumps come with state-of-the-art features like microprocessor-based programmable controls with 1400 steps of flow rates, programmable timers from 1 min to 24 hrs, auto-stop function with audible alarm, and in-built battery back-up to store memory in case of power failure. The pumps also come with RS232 interface for compatibility with personal computers, and they can run with a wide range of tube sizes. The PP series peristaltic pumps are ideally suited for research and process applications, like fermentation, chromatography, acid/ base dispensing, aspiration of tissue culture medium, circulation of coolant in low temperature baths, electrophoresis, flow injection analysis, nutrient supply for cultures, toxicology, pharmacology, etc. Also offered are syringe pumps with flow rate 0.1 ml/hr to 125 ml/hr. These pumps have state-of-the-art features, like microprocessor-based controls and programmable timer.

Miclins India, Chennai 600 044. Tel: 044-2478 1913, Fax: 044-2435 8487, Mob: 09444364648 Email: miclins@eth.net, Website: www.miclinsindia.com

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As the hollow spheres coated in abrasive grain wear down, new grain is constantly being exposed. Some of the benefits include: consistent surface finish & roughness values on workpiece, throughout tool life; 3-5 times the tool life improves economy compared to conventional grinding belts: reduced grinding belt change times & reduced disposal costs for used grinding belts; and lower grinding temperatures. Bharat Udyog, Mumbai 400 064. Tel: 022-2882 8419, Fax: 022-2881 2186 Email: bharat@riabrasive.com, Website: www.riabrasive.com

COKE FEEDING MACHINES urface International offers coke feeding and electronic weighing systems along with rotor-type coke injection machines (model S-1C-FW-SR). These machines come with electric motor, material conveying hosepipe and metallic lance as per standard specifications. They are also available with 2.5 cubic meter feed hopper, weighing system & microprocessor-controlled material feeding system, with in flight correction facility system, control panel & variable drive AC unit, along with motor and gearbox. The machines consist of parts, such as: material hopper having volumetric capacity of 2500 litres mounted on load cells for measuring weight; screw drive with 2 HP variable AC drive augur controlled by PLC; and coke injection discharge unit, complete with 10 meter hose pipe & hot gunning lance.

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Surface International, Jodhpur 342 008. Tel: 0291-2787749, Fax: 0291-2721778, Mob: 09413329749 Email: info@surfaceint.com, Website: www.surfaceint.com

HVOF CONTROL PANELS etallizing Equipment Co offers HVOF control panels (model MP-2100) that are most important and heart of the HIPOJET-2100 HVOF powder spray systems. This equipment is for regulating and measuring the flow of oxygen, fuel gas and compressed air to the HVOF flame spray gun. The flow meter, connected between the gas supply and the gun, is a reliable indicator of gas flow, to warn of obstructions or leakage in the gas lines and an aid to coating quality. Gases used for flame spraying are usually supplied from standard compressed gas cylinders or in-plant pipe lines. For heavy-duty service, it is customary to manifold several cylinders together.

Metallizing Equipment Co Pvt Ltd, Jodhpur 342 005. Tel: 0291-2747601, Fax: 0291-2746359 Email: sales@mecpl.com, Website: www.mecpl.com

ABRASIVE SUCTION BLASTING CABINETS ushal Udyog manufactures and offers abrasive suction blasting cabinets (model KU-S) that facilitate blast-cleaning operation with a confined area. These equipment works on inductionsuction principle of abrasive blasting. A partial vacuum created by high velocity airflow draws abrasive media from the storage

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hopper into the blast gun. Abrasive particles issues out of the blast gun strike the work surface placed inside the cabinet to perform blast-cleaning operation. The split abrasive is recovered and recirculated while the dust and debris are separated from the system. Exhaust air to atmosphere is clean and pollution-free. The abrasive suction blasting cabinets are best suitable for blast cleaning, deburring, descaling, removing thin deposits on soft metallic parts and deflashing of plastic moulded components. They are also used to provide matt finish on metal components. The abrasive suction blasting cabinets are designed to most convenient operating position with ergonomic armholes for free manoeuver of the job/blast gun. Kushal Udhyog, Jodhpur 342 005. Tel: 0291-2720072, Fax: 0291-2724400, Mob: 09414301701 Email: kushaludg@sancharnet.in, Website: www.kushaludhyog.com

FLANGE-MOUNTED BRAKES nco Dynatorq manufactures and offers DC electromagnetic flange-mounted brakes (type 14.115) that are available with slotted wear compensation adjustment. Features include: torque in 7.5 HP to 2500 NM; single plate dry-type; zero backlash, residual-free, fast switching times, high operating reliability, high operating frequency, compact dimensions, simple construction, maintenance-free, raw materials to DIN standards, long life, unique pre-stressed spring, coil

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with class-F insulation, stationary field (no slip rings), non-asbestos special friction material, consistent operating characteristics, simple installation, simple wear compensation adjustment, low inertia of rotating parts, and no restriction on mounting positions. Emco Dynatorq Pvt Ltd, Thane (W) 400 602. Tel: 022-2540 5488, Fax: 022-2545 2233 Email: mktg@emco-dynatorq.in, Website: www.emco-dynatorq.in

SPRING CLAMP DISCONNETING TERMINAL BLOCKS ertain control applications require the circuit to be disconnected without removing the wires. Type CSCDK2.5T and CSCDK2.5T/4 spring clamp disconnecting terminal blocks offered by Connectwell Industries are useful for current and instrument transformer connections. In both the terminal blocks, disconnection is achieved by lifting a lever, which operates a knife contact. Type CSCDK2.5T facilitates 1-in 1-out type connection and CSCDK2.5T/4 facilitates 2-in 2-out connections with connection possibility from wire size 0.5 to 2.5 sqmm. Technical specifications for both types include: material of PA 66; clamping range for stranded wire is 0.5â&#x20AC;&#x201C;2.5 sqmm & for solid wire 0.5â&#x20AC;&#x201C;4 sqmm; rated voltage is 600 V; and current rating is 16 A. Type of connection for type CSCDK2.5T is 2 spring clamp connection with 1 disconnecting link; and for type CSCDK2.5T/4 it is 4 spring clamp connection with 1 disconnecting link.

Connectwell Industries Pvt Ltd, Dist Thane 421 204. Tel: 0251-287 0766, Fax: 0251-287 0889 Email: sales@connectwell.com, Website: www.connectwell.com

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HOLLOW CONE SPRAY NOZZLES praytech Systems (India) offers hollow cone spray nozzles that work on the tangential flow principle. These spray nozzles are manufactured by machine tool operation from metal bar stock. They offer versatile construction of small-sized nozzles. In addition, the hollow cone spray nozzles can also be made on request from any special materials and alloys that are available as a bar stock. They are available in vaneless (two-piece construction) non-clogging design. Applications are in cooling & cleaning of air/gas; dust suppression; spray drying; filter cleaning; and desuperheating. The hollow cone spray nozzles are also available in other types, such as tangential entry, inline (axial) entry, spiral hollow cone, etc.

Spraytech Systems (India) Pvt Ltd, Thane (W) 400 604. Tel: 022-2582 8929, Fax: 022-2581 2861, Mob: 09987584555 Email: kharade@spraytechindia.com, Website: www.spraytechindia.com

MICROWAVE RANGE FINDERS

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K Instruments offers microwave range finders (model MWSRF Micro-Ranger) manufactured by Wire Automatic Device Co, Ltd, Japan. These instruments consist of an antenna connected to a controller by circular waveguide tubing. The heat-resistant antenna is installed in the high temperature zone, while the controller is located in a room temperature area allowing the sensor to make accurate measurements in high temperature areas without special cooling. Some of the features of the microwave range finders include:

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unaffected by adverse conditions; high accuracy & reliability; operational state shown on the PC; convenient built-in functions; lightweight & compact; and high versatility. D K Instruments Pvt Ltd, Kolkata 700 031. Tel: 033-2405 0944, Fax: 033-2415 2311, Mob: 09433208550 Email: info@dkinstruments.com, Website: www.dkinstruments.com

FORGED CARBON STEEL FLANGES enus Fittings & Valves manufactures and offers forged carbon steel flanges. These are available in slip-on, blind, threaded, socket-welded, lapped and welding-neck types. The material of construction is forged carbon steel ASTM A105. Dimensions are ANSI B16.5/BS 1560 150# and 300#, BS 4504. Size ranges from 15 mm to 300 mm.

Venus Fittings & Valves Pvt Ltd, Mumbai 400 015. Tel: 022-2412 3151/7006, Fax: 022-2413 5576, Mob: 09327988509 Email: inquiry@vfvl.com, Website: www.vfvl.com

HIGH-POWER DRIVES anfoss Industries offers VLT high-power drives in a wide range up to 1.2 MW capacity. These drives are available with input voltages ranging from 380 V to 690 V AC. The high-power VLT drives have the potential and the flexibility to be engineered for a wide variety of demanding industrial applications in steel, cement, paper and power sectors. These drives offer a cost-effective alternative to direct medium voltage drives, ie, the Hi-Lo-Hi power configuration in which a standard low voltage drive can be effectively engineered as a medium voltage drive with the use of input and

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output transformers. The high-power drives are characterised by a high degree of compactness, an efficient cooling system and high module efficiencies. The unique duct cooling system and the flexibility to have back and front channel cooling options confers many advantages to the user in terms of reduced installation space and running costs. Danfoss Industries Pvt Ltd, Chennai 600 119. Tel: 044-5550 1555, Fax: 044-5500 1444 Email: danfoss.india@danfoss.com, Website: www.danfoss.com

CHECK VALVES ormex Valves manufactures and offers ball-type check valves (non-return valves) with unique design. These are available in very simple but robust design with no critical mechanism involved. All parts, like hinge-pin-disc mechanism used in conventional valves are eliminated. The ball, moves totally out of the flow path when the pumping is on to give minimum head losses. Spherical rubber coated ball seals perfectly on the rounded valve seat ensuring a totally leakproof sealing. This design offers other advantages like non-clogging and self-cleaning. In these virtually maintenance-free valves, if required, after prolonged usage, the online replacement of the ball is just a minute job. Features include: lower power consumption, larger solid handling capacity, selfcleaning, non-clogging, perfect sealing, low-pressure drop, etc.

Normex Valves Pvt Ltd, Pune 411 026. Tel: 020-2747 2398, Fax: 020-2747 3022 Email: svkoparde@vsnl.com, Website: www.normexvalves.com

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STEP MOTORS & DRIVES trategi Automation Solutions offers two-phase and five-phase step motors and drives manufactured by Mycom of Japan. Fivephase motors are available from 2 kgcm to 63 kgcm holding torque. These five-phase motors offer superior smoothness, low resonance, higher torque and speed capabilities. Standard version UPS 503 has both full and half step capability and the high-performance version INS 500 has nano stepping up to 5,00,000 steps per revolution. Two-phase motors are available from 2 kgcm to 95 kgcm. Motor resolution is 200 steps per revolution. IMS200 low-cost bipolar chopper DC input drives can run the motors up to 2 A per phase current. These drives also have micro-stepping from 200 to 1600 steps per revolution. AC input drives are also available that have full and half step mode. The drives are suitable to drive motors to higher speeds. Applications abound in X-Y tables, coil winding, cut-to-length, packaging, etc.

Strategi Automation Solutions Pvt Ltd, Mumbai 400 072. Tel: 022-2847 3114/15, Fax: 022-2847 3114 Email: amitha@strategiautomation.com Website: www.strategiautomation.com

ROLLER BELT CONVEYORS rmstrong Machine Builders offers roller belt conveyors that are designed and manufactured using rigid structural profiles and assembled using various standard system components. A large selection of belt types complement the compact frame height of 50 mm dia, 52 mm drive roil, which is available in either a steel or rubberised version depending on the application. All belt conveyor

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systems feature crowned rollers, which significantly simplify belt tracking. Features include: rigid aluminum profile structure; drive & tail options as per functions; variety of belt types; crowned rollers simplify belt tracking; stainless steel slider bed; maintenance-free dual-sealed bearings; 10 mm T-slot along the length gives flexibility of integration; and wide options of standard side rails & stands. Applications are in small parts handling parts accumulation, vision inspection, incline & decline operations, printing/labeling & scanning, stamping, injection moulding, packaging, etc. Armstrong Machine Builders Pvt Ltd, Pune 411 038. Tel: 020-2545 8841, Fax: 020-3026 3713, Mob: 09637107258 Email: sales@armstrongltd.com, Website: www.armstrongltd.com

ELECTRONIC FREQUENCY INVERTERS mco-Kimo Electronics India offers electronic frequency inverters (model MotorMaster MM1 & MM2) with integrated EMC filter (class B limit). These frequency inverters have speed control of three-phase induction motors at powers up to 2.2 kW. Features include: universally suitable for general industry applications with a constant torque requirement as well as for fans and pumps with a quadratic load characteristics; optimum cost/performance; sine wave modulation in the full speed range; special low-noise statistically controlled quiet pattern 4 kHz PWM; operation with frequency up to 240 Hz ; simple user-friendly programming with help of a three-character display; four function keys which also provide local-mode operation; advanced multi-level protection; and programming adapter for smart cards. The electronic frequency inverters are used in transport & material handling;

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pumps; heating & ventilation fans; refrigeration compressors; long & cross travel drives; packing machines; and general applications requiring speed control in mechanical engineering & process plant. Emco-Kimo Electronics India Pvt Ltd , Mumbai 400 055. Tel: 022-2665 1771-75, Fax: 022-2665 1777, Mob: 09324254557 Email: emcokimo@emcoinfo.com, Website: www.emcoinfo.com

STAINLESS STEEL TIES urelock Plastics offers stainless steel ties and tagging systems. For fire hazards, corrosive environment and extreme weathering conditions, the cable bundling/clamping application needs safe, strong and worry-free cable ties, as plastic ties are simply inadequate or even dangerous for such applications. Hence, the stainless steel cable ties are ideally suitable. These are made out of SS grades 316, 304 & 201 depending upon the application & customersâ&#x20AC;&#x2122; requirements. The steel ties are coated with non-toxic halogen-free low smoke & UV resistant polyester, PPA, nylon, materials, which provides handling comfort at extreme low temperatures, extra protection against corrosion, impedes weathering effect and protect the bundle. These are available in a wide choice of colours. All raw materials are tested before going for production. The steel ties meet international tensile strength ratings. Applications are in offshore, ship building, petroleum, chemical, automobile industries, communication, aerospace, thermal, nuclear projects and in general industries.

Surelock Plastics Pvt Ltd, Mumbai 400 002. Tel: 022-2205 4545, Fax: 022-208 3001, Mob: 09757407376 Email: surelock@hathway.com, Website: www.surelockcableties.com

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COOLING TOWER GEARBOXES lecon Engineering Company manufactures and offers several sizes of gearboxes for cooling tower application, which are designated as KBV-NL. These are two-stage gearboxes having 1st stage out of spiral bevel pair duly case hardened and lapped with another helical pair with case hardened and ground. Normally output shaft is vertically upward which takes the dynamic thrust of fan as well as dead weight of the same by virtue of thrust bearing, which is provided in the gearbox. Bevel helical with horizontal input and vertically upward output shaft is a special feature of the gearboxes. An advantage is that these cooling tower gearboxes are specially designed for cooling tower drives with heavy-duty bearings on output shaft to take care of external load. The gearboxes are used for cooling tower drives. They are available in the ratios ranging from 6.3 to 18 and power range of 13 kW to 500 kW.

Elecon Engineering Company Ltd, Vallabh Vidyanagar 388 120. Tel: 02692-236513, Fax: 02692-236527 Email: infogear@elecon.com, Website: www.elecon.com

DIGITAL PRESSURE GAUGES aris Sensor Technologies offers LED digital pressure gauges that are microprocessor-based units, which can operate with an internal resolution of 40,000 div max (full scale can be presetted in accord with each application). In order to increase the integration level of the components, a combined traditional and SMT technology has been applied. This results in a pressure gauge more resistant against mechanical stresses and vibrations besides

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ensuring maximum reliability of the electronic circuit. The instrumentsâ&#x20AC;&#x2122; results are very versatile, thanks to the possibility to transmit any data through the RS232C output connected to a computer or an intelligent peripheral. Two digital set points are available with power relay and analogue output, which can be: in voltage 0-5 V or 0-10 V and in current 4-20 mA. For very dynamic applications, to increase resulting stability, the digital pressure gauges are equipped with a very programmable digital filter. Haris Sensor Technologies Pvt Ltd, Navi Mumbai 400 708. Tel: 022-2769 6901, Fax: 022-2769 6906 Email: harisent@vsnl.net, Website: www.harissensor.com

MULTI-FUNCTIONAL POWER METERS B Control & Systems offers PM130EH+ Plus multifunctional 3-phase power meters. This series provides a cost-effective substitute for numerous analog meters used by industrial, commercial and utility customers for basic power metering. It is also suitable for utility substation automation because of its support of the industry standard DNP V3.0 and Modbus RTU protocols, as well as its I/O capabilities (using DI/DO module). These power meters can provide more than

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80 parameters, via local display and more than 100 parameters, via communication interface. Each meter has serial RS485 communication port as standard. A wide choice of additional plugin modules includes digital I/O, analogue output, TOU, Ethernet and Profibus. Features include: voltage, current (including neutral current), power, energy, power factor, frequency, voltage/current unbalance; current over range up to 200 per cent; and sampling rate of 128 samples per cycle for each phase voltage & current. M B Control & Systems Pvt Ltd, Kolkata 700 019. Tel: 033-2287 3791, Fax: 033-2287 0445, Mob: 09748899011 Email: mbcontrol@vsnl.com Website: www.mbcontrol.com

BARE PUMPS lorida International offers Graco total drum emptying solution (model Bulldog 10:1) that are also called as bare pumps. These USDAapproved pumps feature 303 stainless steel wetted construction and can be fitted with the optional adjust-a-stroke air motor to provide accurate volumetric metering to Âą2per cent. The bare pumps are ideal for materials up to 1,000,000 CPS, which have poor flow characteristics and usually require ram pressure to level the product and feed the pump inlet. Features & benefits include: delivery up to 8 GPM (31 LPM); fluid outlet pressures up to 1000 PSI (70 bar, 7 MPa); and 303 stainless steel wetted construction. Applications are in fluid transfer and supply of high viscosity non-flowable fluids.

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Typical fluids handled are peanut butter, ricotta cheese, cream candy filling, moist pet food, etc. Florida International, Mumbai 400 003. Tel: 9867685186 Email: imran@floridainternational.net Website: www.floridainternational.net

DUAL UNIVERSAL CARTRIDGE SEALS i-Fab Engineers manufactures and offers dual universal cartridge seals (type DSBC) that can work in back-to-back as well as tandem mode. These cartridge seals have common springs to reduce installation errors. Three out of four faces are identical and interchangeable. The seals can easily fit into ANSI, DIN, and ISO standard bore pumps. They have tangential ports for effective circulation of barrier/buffer fluid. The dual universal cartridge seals have stationary spring design and monolithic seal faces. They can also tolerate pressure reversal. Applications are in pulp & paper plants, vacuum distillation, crystallising solutions, hazardous liquids, etc.

Hi-Fab Engineers Pvt Ltd, Mumbai 400 101. Tel: 022-4076 6555, Fax: 022-4076 6556 Email: info@hi-fab.com, Website: www.hi-fab.com

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SUBMINIATURE D FILTERS arting has developed a range of filter solutions to help designers of electronic equipments to achieve the demanding goal of electromagnetic compatibility. The company offers a wide range of solutions by the integration of a filter inside one of the most standard I/O ports on the market; the Dsub. From standard simple ferrite-filter solution to complex customised highperformance filters, one can find in the Harting filter D-sub range the adequate solution to protect oneâ&#x20AC;&#x2122;s application from any introduction or radiation of noise through D-sub port apertures. Some of the advantages include: compatible with standard wave and lead-free reflow soldering (C-filter); same layout and shell dimensions as standard D-sub connectors, no modification of PCB design necessary; elimination of ringing, crosstalk phenomenon, thanks to specific multi-layer PCB used in C-filter design; and flexible filter structure allowing a wide range of customisation.

Harting KGaA, Germany Tel: +49-577247-244, Fax: +49-577247-400 Email: wulf.padecken@harting.com, Website: www.harting.com

LASER MODULES -Laser Optoelektronik manufactures and offers laser modules (model ZM18B-F) that are standard and customised type modules. Salient features of these laser modules include: 5-30 V

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DC operation; power up to 200 mW; red, infrared laser wavelengths available; gaussian/ uniform line optics & various DOE available; simple, external hand focusing mechanism; IP67 rated & fully waterproof; threadmounted for simple & versatile mounting; LED laser operation indicator; over voltage protection with surge/spike protection; and reverse polarity protection. Applications are in positioning, wood processing, metal processing, textile industry, stone processing, food industry, medical science, automotive industry, etc. Z-Laser Optoelektronik GmbH, Germany Tel: +49-761-2964432, Fax: +49-761-2964455 Email: z-laser@t-online.de

SENSORS ontrinex manufactures and offers sensors with analogue output. Classical (switching) proximity switches work internally as analogue devices, although they produce a binary signal at the output. A large part of the available internal information, though, is lost. Switches with analogue outputs, on the other hand, provide the user with full information, permitting a variety of possible applications. Proximity switches already work as analogue devices. However, a signal shaper before the output stage changes the rectified analogue signal into a digital one. This signal shaper also exists in switches with analogue

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outputs, but there it serves an entirely different purpose. Instead of producing a switching point, it converts the signal emitted by the rectifier into a more usable, but still analogue, form. Main purpose is the generation of defined starting and end-points of the output function, as well as a defined flow in between. Contrinex GmbH, Germany Tel: +49-2153-73740, Fax: +49-2153-737455 Email: info@contrinex.de, Website: www.contrinex.de

ALUMINIUM ALLOY PROFILE TUBES ee Young Industrial Co manufactures and offers aluminium alloy profile tubes (model YT T6A) that are especially designed for pneumatic cylinder use. Materials of construction include aluminum alloy 6063 T5. Through anodising, aluminum tube with smooth surface is unnecessary for further repainting process. The aluminum alloy profile tubes are available with great quality, lightweight and anti-corrosion. They are suitable for pneumatic cylinders, portable devices, and various types of air pressure and pneumatic equipment, etc.

Yee Young Industrial Co, Ltd, Taiwan Tel: +886-4-7990077, Fax: +886-4-7992277 Email: yy799@ms.22.hinet.net, Website: www.fluid-power.com.tw

SURGE CAPACITORS

o offer environmentally friendly, leak-proof and safe products to the market Electronicon Kondensatoren has developed

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a full MV range of surge capacitors in totally dry construction. This range is now extended by the launch of a new range of surge capacitors (series E93) for the protection of transformers and electrical machines. Surge capacitors are required to reduce the steepness of the wave front of the surge and protect the turn-to-turn insulation. Generally used along with a surge arrestor, the surge capacitor is one of the most important protection elements to increase the longevity of electrical machines. These capacitors are manufactured using metallised polypropylene film and filled with solid PUR, thereby making them the first with dry technology. A special plastic coating makes these tubular type capacitors a step away from the conventional bulky all-film oil-filled capacitors. With their simple connections the surge capacitors are a big advantage for the indoor surge protection requirements. Electronicon Kondensatoren GmbH, Germany Tel: +49-365-7346100, Fax: +49-365-7346110 Email: sales@electronicon.com, Website: www.electronicon.com

SPECTROMETERS pectro Analytical Instruments offers Spectro Genesis, the first and only ICP-OES spectrometer available with a complete set of factory methods truly plug-&-analyse without needing to first develop a method. These factory methods cover all common environmental and industrial applications, like water, wastewater, industrial wastewater, soil, sewage sludge, filter dust, wear metals in oil and additives in oil. Compliant to national and international norms, they are delivered ready for use straight out of the box

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with an application package that includes the sample introduction system, sample preparation instructions and method documentation. An extensive package of accessories is available for the Spectro Genesis to further expand its application range. The Spectro Genesis offers a real economic alternative to sequential ICP and atomic absorption spectrometers, enabling those who are unfamiliar with ICP to profit from the advantages of leading CCD ICP technology and to use a powerful, low cost and user-friendly analytical system. Spectro Analytical Instruments GmbH & Co KG, Germany Tel: +49-2821-8922106, Fax: +49-2821-8922206 Email: gisela.becker@ametek.com, Website: www.spectro.com

HOISTS

heng Day Machinery Works Co manufactures and offers a wide range of hoists for use in diverse applications around the world. Electrical chain and wire rope hoists offer handle loads in manufacturing environments and related facilities where heavy items must be lifted and positioned as part of the production or warehousing processes. Numerous manually operated products are available with hand chain hoists and lever hoists that are used primarily during maintenance and construction activities.

Cheng Day Machinery Works Co, Ltd, Taiwan Tel: +886-4-26881581, Fax: +886-4-26881509 Email: info@chengday.com.tw, Website: www.chengday.com.tw

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LOW HARMONIC DRIVES anfoss A/S manufactures and offers VLT low harmonic drives that are frequency drives built on the power and control platform of the new generation VLT drives. The difference is that these low harmonic drives eliminate the harmonic disturbances on the supply grid by actively imposing currents into the grid so that the high quality sine wave of the grid current is restored. Like the other VLT frequency drives, the VLT low harmonic drives have a modular build-up and a highenergy efficiency, back-channel cooling and user-friendly operation. The VLT Aqua drives, VLT HVAC drives and VLT automation drives are available in this new low harmonic version. Where the performance of other low harmonic technologies depends on stability and load or effect the controlled motor, the new VLT low harmonic drives continuously regulate the network and load conditions without affecting the connected motor.

Danfoss A/S, Denmark Tel: +45-74882222, Fax: +45-74880949 Email: danfoss@danfoss.com, Website: www.danfoss.com

INSULATION RESISTANCE TESTERS luke Corporation has introduced the new Fluke 1555 and redesigned Fluke 1550C insulation resistance testers designed for a wide range of diagnostic and predictive maintenance programs. These testers offer digital insulation testing up to 10 kV (Fluke 1555), making them ideal for testing a wide range of high voltage equipment including switchgear, motors, generators and cables. They can conduct the entire range of test

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voltages specified in IEEE 43-2000 with a best in class, three-year warranty and CAT III, 1000 V, CAT IV 600 V safety rating. With measurement storage and PC interface, the Fluke 1555 and Fluke 1550C are perfect tools for long-term equipment monitoring. Warning function alerts users that line voltage is present and gives the voltage reading up to 600 V AC or DC for increased user safety. Measurements can be stored up to 99 memory locations, with each location assigned a unique, user-defined label for easy recall. Fluke Corporation, USA Tel: +1-425-3476100, Fax: +1-425-4465116 Email: service.status@fluke.com, Website: www.fluke.com

ROTARY WIRE STRIPPERS he Eraser Company, Inc manufactures and offers rotary wire strippers and twisters (model C100S) that process insulations from solid and stranded wires, such as Teflon, PTFE, PVC, nylon, KEL-F, etc. Strip length and blade depth adjustments must be made while the machine is running. These rotary wire strippers can be used to remove insulation slugs and twist together strands of stranded conductors.

The Eraser Company, Inc, USA Tel: +1-315-4543237, Fax: +1-315-4543090 Email: info@eraser.com, Website: www.eraser.com The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of

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To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;Product Indexâ&#x20AC;&#x2122; or write to us at search@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Product

Pg No

Abrasive blast rooms 169 Abrasive blasting machines 169, 181 Abrasive suction blasting cabinets 195 AC & DC power packs 206 AC motors 59 AC/DC panels 170 Accumulators 206 Acoustic enclosures 153 Actuators 184 Adhesives 225 Adjustable adaptors 91 Adjustable shock absorbers 176 Air compressors 127 Air dryers 167 Air nozzles 187 Air operators 84 Air purifiers 97 Air-cooled reciprocating compressors 127 Airless shot blasting machines 84 Airport passenger baggage trolleys 223 All-geared pillar drilling machines 156 All-geared planning machines 219 All-geared radial drilling machines 156 Alloy wheels 223 Alu-cera polymers 9, 15 Aluma coats 9, 15 Aluminium clamps 155 Aluminium high-precision components 149 Aluminium oxide ceramic composites 9, 15 Aluminium worm geared motors 122 Aluminum extrusion 207 Ammeters 192, 199 Analogue & digital panel meters 17 Analogue panel meters 17 Appliance switches 29 Area sensors 73, 121 AS ser ies gearboxes 20 Assembly technology 67 Auto drains 180 Auto transfer systems 173 Autoclavable gaskets 200 Automatic rolling shutters 23 Automation & storage systems 49 Automation drives 183 Automation 10, 139, 244 Auxiliary equipment 174 Aviation cog wheels 187 Bakelite products 224 Baking ovens 84 Balancers 101 Ball & roller bearings 68 Ball bearings 207 Ball check valves 63, 107 Ball joints 117 Ball transfer units 223 Ball valve spindles 177 Ball valves 63, 107, 162, 163, 177 179, 184, 220, 222 Balls 209 Bare pumps 208 Basket strainers 163 Batch counters 206 Battery-operated pallet trucks 131 Bearing bushes 187 Bearings 12, 68, 207, 243 Belt-type magnetic concentrators 52 Bench drill presses 172 Bending machines 159 Bends 179 Billet shearing machines 14 Bio toilets 205 Blast room paint spray booths 84 Blasting media 169 Blowers 190 BMS systems 221 BNC plugs & sockets 152 BOD controllers 206 Bollards 23 Boring machines 219 Braided hoses 200 Brake motors 43, 59, 122, 140 Brass cable glands 149 Brass castor wheels 223 Brass components 149, 152, 218 Brass connectors 152 Brass inserts 149 Brass meter parts 149 Brass parts 149, 218 Brass turned precision components 218 Breather valves 162, 163 Brine chillers 197 Bronze wheels 223 Brushless DC motors 20 Brushless motor controls 20

226

Product

Pg No

Building automation 244 Bushes 107 Bust preventives 188 Butterfly valves 63, 107, 167, 177, 179, 220 Cable carriers 12 Cable clamps 185 Cable connectors 12 Cable glands 47, 149, 185, 186 Cable handling & processing systems 49 Cable markers 185 Cable reeling drums 52 Cable scanps 49 Cable ties 47, 185 Cable trays 155 Cables & leads for fixed instaction 49 Cables 43, 49, 86, 111, 205 Calendaring Front gatefold Calibrators 5, 10 Carbide rods 113 Carbon fibre reinforced products 187 Cast/extruded 167 Castings 186 Castor wheels 223 Castors 223 CED coating machines 244 Centralised lubrication systems 66 Centreless grinding machines 203 Centrifugal blowers 127 Centrifugal compressor package 127 Centrifugal oil cleaners 205 Centrifugal oil water separators 205 Centrifugal pumps 41 Ceramic adhesive cements 9, 15 Ceramic electrical heater parts 9, 15 Ceramic processing furnaces 174 C-frame power presses 14 Chain pulley blocks 140 Chains 12 Chair castors 223 Channel magnets 173 Check valves 163, 188, 202, 220, 222 Chemical process pumps 162, 224 Chemical pumps 166 Chemical vane pumps 187 Chemlok coating machines 244 CI castings 219 Circlips 188 Circular motion vibratory screens 52 Circular vibratory screens 52 Circular/gyrator vibro machines 173 Cistern type manometers 163 Cleats 155 Clutches & brakes 20 CNC cutting machines 244 CNC laser cutting machines 244 CNC machine solutions 160 CNC machines 186, Back inside cover CNC oxyfuel cutting machines 244 CNC plasma cutting machines 244 CNC tap chucks & tap adaptors 91 CNC tap holders & pull studs 91 CNC tools holders & pulley studs 91 CNC turning centers Back inside cover CNC vertical machining centres 13, Back inside cover CNC/VMC machines 95 Coating machines 244 Coating plants 244 Coating systems 244 Coaxial cables 86 Coke feeding machines 192 Cold form C & Z purlins 54 Cold storage dockhouses 23 Cold storage doors 23 Command panel systems 38 Compressed air division 204 Compressed air systems 50 Compression fittings 189 Compressor valve plates 187 Compressors 45, 50, 127 Concrete vibrators 52 Conductors 155, 205 Conduit & fittings 186 Conduits & connector systems 29 Cone pulley heavy-duty lathe machines 223 Cone pulley light-duty lathe machines 223 Cone pulley medium-duty lathe machines 223 Connectors accessories 49 Connectors 6, 12, 24, 47, 172 Console systems 38 Container cranes 109 Contrast/colour scanners 103 Control & automation 111 Control panel accessories 29

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Product

Pg No

Control relays 199 Control valves 177 Controllers 10 Conventional & monoblock pumps 145 Conventional pallet racking systems 200 Conveyor castor wheels 223 Conveyor trolleys 223 Conveyors & automation systems 23 Coolant accessories 145 Coolant pumps 145 Coolant rotary unions 176 Cooling tower gearboxes 206 Cooling tower motors 122 Cords 200 Core drilling units 172 Corrosion preventives 188 Counters & power supplies 7 Counters rate products 10 Counters 121, 206 Cover blocks 172 Crab hoists 140 Crane-duty motors 43, 122, 140 Cranes 18, 119, 10, 198 Crimp contacts & tools 49 Crocodile clip cords 152 Cross belt inline magnetic separators 52 Current sensors 205 Cushion dock shelters 23 Custom-made cables 49 Cutting machines 244 Cutting tools 113, Front gatefold Cylindrical dowel pins 188 Cylindrical grinders 203 Cylindrical sensors 103 Dairy monoblock pumps 195 Data cables 49 Data loggers 206 DC motors 59 Demagnetisers 201 Demand controllers 191 Descaling headers 208 Dessicant dryers 127 Diamond coated needle files 208 Diaphragm switches 186 Diaphragm valves 63, 107, 167, 179 Digital almen gauges & strips 115 Digital flow meters 195 Digital mark sensors 73 Digital multimeters 17 Digital panel meters 121, 150, 191, 192 199, 206, 219 Digital preset timers 150 Digital pressure gauges 206 Digital temperature controllers 80 Digital vibration meters 152 Dip spin coating machines 244 Dip-pipes 63 Disc brakes 197 Disc washers 188 Display units 121 Distribution boards 16, 155 Dock levellers & dock shelters 23 Dock shelters 188 Door runners & tracks 223 Door side sensors 121 Dosing feeders 52 Double drum & triple drum magnetic separator 201 Double sheet monitoring 103 Drawer magnets 173, 201 Drill chucks 204 Drill machines 156, 204 Drill sleeves 91 Drilling machines 101 Drive motors 166 Drivers & controllers 121 Drives 21, 80, 195 Drum trolleys 200, 223 Drum-type magnetic separators 52, 173 Dry vane pumps 153 Dual channels 80 Dual universal cartridge seals 209 Dust collectors 169 Dynamic controllers 80 Earth leakage relays 191 Elbows 63 Electric actuators 158 Electric controls 67 Electric dock levellers 200 Electric drives 67 Electric drum lifters 200 Electric forklift trucks 23 Electric hoists 119 Electric lifting platforms 200

Product

Pg No

Electric motors 231 Electric pallet trucks 200 Electric scissor lift tables 200 Electric stackers 200 Electric walkie stackers 200 Electric wire rope hoists 18, 119, 140 Electrical actuators 173 Electrical connectivity 155 Electrical connectors 117 Electrical measuring instruments 170, 192 Electrical products 47 Electrical systems 111 Electrical transducers 17 Electromagnetic bin vibrators 52 Electromagnetic disc brakes 197 Electromagnetic ferro-filters 52 Electromagnetic vibratory feeders 173 Electronic energy meters 191 Electronic frequency inverters 204 Electronic timers 30, 32, 34, 36 Electronics For You Expo-2011 210 Electronics products 47 Electronics 152 Embossing rolls Front gatefold Emergency shock absorbers 176 Enclosure cooling units 38 Enclosure systems 38 Encoders 5, 7 End caps 179 Energy conservation 137 Energy efficient motors 122 Energy efficient pumps Front inside cover Energy efficient solutions 237 Energy management solutions 191 Energy saving gas burners 174 Engineering Expo exhibition 193, 245 Engineering plastic plugs & sockets 30, 32, 34, 36 Engineering plastics 167 EOT cranes 18, 119, 140 EOT jib cranes 198 ERP/SAP/LIMS/DMS/clinical database systems 221 Exhausters 190 Exhibitions 151, 154, 168, 178 182, 193, 210, 245 Expansion bellows 63 Explosive meters 71 Fabtec India-2011 exhibition 151 Factory automation 139, 244 Failsafe brakes 197 Fan & filter units 38 Fasteners 101, 149, 152, 188 FBD gaskets 200 FEP/PFA/PVDF materials 107 Ferrous & non-ferrous high precision parts 149 Ferrous castings 207 Fiberoptic sensors 121 Fibre sensors 73 Fibreoptic amplifiers 103 Files 208 Filter cocks 179 Finishing machines 173 Fire safe ball valves 220 Fire shutters 23 Fittings 107 Flame arresters 162, 163 Flameproof motors 59, 122, 195 Flameproof products 10 Flange motors 43 Flange mounting motors 59 Flange-mounted brakes 197 Flanging machines 159 Flat cables 49 Flat high-tension single-twin igniting electrodes 9, 15 Flexible cables & wires 49 Flexible shafts 195 Floating holders 91 Floor plates 219 Floor scrubbers & dryers 229 Flooring 179 Flow indicators 179 Flow instruments 217 Flow rate indicators 10 Flow switches 163 FLP junction boxes 183 FLP starters 183 FLP WG lighting fixtures 183 FLP WP control panels 183 Fluid dispensing parts 187 Fluidised bed coating machines 244 Flush bottom ball valves 220 Flush bottom tank valves 222 Flush bottom valves 63, 163 Flux generators 52

PRODUCT INDEX

Product

Pg No

Foot mounting motors 43 Foot valves 179 Force actuation 147 Forged carbon steel flanges 201 Forged components 207 Forged parts 149 Forged steel & cast iron gates 188 Forging presses 14 Forked photoelectric sensors 103 Forklift trucks 79 Frequency meters 170, 192 Friction drop hammers 14, 156, 203 Friction screw presses 14 FRL spares valve spares 180 Front casings 166 FRP cable trays 155 FRP ladders 155 FRP light poles 155 Funnel magnets 173 Furniture castor wheels 223 Furniture castors 223 Gantry cranes 140, 198 Gas alarms 71 Gas analysers 71 Gas control & regulators products 177 Gas detection systems 71 Gas detectors & monitors 71 Gas sensors 71 Gas springs 176 Gas trains 177 Gaskets 107, 200 Gate valves 220, 222 Gates 188 Gauge accessories 217 Gearboxes 203 Gear motors 20 Gear operators 189 Gear pumps 209 Gear seals 187 Geared boxes 165 Geared head heavy-duty lathe machines 223 Geared head medium-duty lathe machines 223 Geared motors 122, 140, 165 Glass processing furnaces 174 Glass 241 Glide coating machines 244 Globe valves 163, 188, 220, 222 Goliath cranes 119, 140 Goods lifts 198 Grab buckets 119 Graphic panels 121 Grill magnets 173 Grinding belts 190 Grinding machines 241 Grinding media 9, 15 Grinding tools 241 Grinding 101 Grooved pins 188 GRP cable trays 155 GRP ladders 155 Haconan-free cables 49 Hammers 14, 156, 203 Hand magnets 173 Handheld vibratory motors 52 Hannover-2010 exhibition 154 Head screws 166 Head washers 166 Heat shrink tubings 47 Heat treatment salts 188 Heating elements 169 Heavy-duty castor wheels 223 Heavy-duty castors 223 Heavy-duty drill machines 204 Heavy-duty industrial castors 223 Heavy-duty lathe machines 192 Heavy-duty radial drill machines 204 Heavy-industrial steel buildings 54 Heli-bevel geared motors 122 Helical geared motors 18 Helical-worm gear units 20 Heli-worm geared motors 122 H-frame power presses 14 High-alumina wear-resistant ceramic tiles 9, 15 High-carbon chrome 209 High-carbon steel balls 209 High-discharge (flooding-type) pumps 145 High-efficiency standard motors 122 High-intensity induced roll magnetic separators 52 High-intensity rare earth magnetic separators 173 High-intensity roller-type magnetic separators 173 High-performance plastics 187 High-power drives 201 High-precision turned parts 149 High-pressure ball valves 184, 222 High-pressure blowers 20 High-pressure cleaners 229 High-pressure triplex plunger pumps 208 High-speed doors 23 HIM 175 HMM technical guidelines 122

228

Product

Pg No

HOC dryers 127 Hoists 119 Hollow cone spray nozzles 200 Hollow shaft worm gear motors 20 Hooper magnets 173, 201 Horizontal boring & facing machines 156 Horizontal boring machine 156 Horizontal CNC machines Back inside cover Horizontal facing machines 156 Horizontal machining centers Back inside cover Hose clamps 156 Hot oil rotary unions 176 House wiring & industrial cables 86 HP-speed blast wheels 84 HRC fuse bodies 9, 15 Human machine interfaces 172 Humidifiers 81 Hump magnets 52, 173, 201 HVOF control panels 195 Hydraulic centerless grinding machines 203 Hydraulic cylinders 222 Hydraulic cylindrical grinders 203 Hydraulic cylindrical grinding machines 203 Hydraulic dampers 176 Hydraulic dock levelers & shelters 23 Hydraulic drum lifters 200 Hydraulic forging hammers 220 Hydraulic gear pumps 206 Hydraulic hoses 68 Hydraulic internal grinding machines 203 Hydraulic manual pallet trucks 131 Hydraulic pallet trucks 200 Hydraulic presses 220 Hydraulic punching machines 159 Hydraulic rotary unions 176 Hydraulic shock absorbers 126, 176 Hydraulic steel working machines 159 Hydraulic valves & fittings 189 Hydraulics 67 IC counterbalanced forklifts 23 Imaging & vision systems 244 Impellers 166, 179 Inclined tube manometers 163 In-cylinder sensors 143 In-cylinder transducers 143 Indexing machines 169 India Energy-2010 exhibition 178 Indicators 10 Induction seals/wads 155 Inductive proximity switches 29 Inductive switches 103 Industrial automation 139 Industrial batteries 111 Industrial ceramics 9, 15 Industrial connectors 49 Industrial control & sensing devices 7 Industrial cooling systems 197 Industrial cranes 109 Industrial electric AC motors 20 Industrial electric power distribution systems 16 Industrial flooring 179 Industrial heating elements 169 Industrial ovens & dryers 174 Industrial overhead doors 23 Industrial pins 188 Industrial shock absorbers 126, 176 Industrial Y-type strainers 184 Information technology solutions 221 Inline drum type magnetic separators 173 Inline helical geared motors 122 Instrumentation & controls 27 Instrumentation made cables 49 Instrumentation 195 Insulated doors 23 Insulation testers 17 Interfacing with mis packages 221 Inter-locking doors 23 Internal grinders 203 Internal grinding machines 203 Inverter duty motors 122 Inverter/variable frequency drives 7 Investment Destination - Maharashtra 232 Isolators 85 Jacketed ball valves 220 Jet cleaning machines 208 Jib cranes 18, 140 Joining 147 Junction boxes 155 K-2010 exhibition 168 Kilns & baths 174 Lab equipment 221 Laboratory testing rerods 52 Large bearings 68 Large enclosures 38 Large helical & heli-bevel gearboxes 122 Laser markers & sensors 73 Laser shaping 241 Lathe machines 192, 219, 223 Lathes 174, 192 Leak detectors 71

SEARCH - THE INDUSTRIAL SOURCEBOOK | S E P T E M B E R 2 0 1 0

Product

Pg No

LED signal tower lights 30, 32, 34, 36 LEDs 29 Level controllers 7, 201 Level gauges 163 Level indicators 201 Level switches 201 Level transmitters for liquids 201 Lift & conveyor cables 49 Lift trucks services 109 Lifting magnets 201 Light lifting 109 Light-duty castors 223 Light-duty lathe machines 192 Limit switch boxes 158 Limit switches 29, 30, 32, 34, 36 Linear hall effect ICs 205 Linear hall ICs 205 Linear motion vibratory screens 52 Linear motion 67 Linear potentiometers 143 Linear sensors 143 Load break switches 29 Load managers 191 Load turning devices 179 Loaders 79 Loading bay equipment 23 Local control stations 155 Long neck pipe ends 179 Loop powered indicators & isolators 10 Lorry loaders 79 Low lift pallet trucks 23 Lubricated plug valves 162 Machine automation 221 Machine tool accessories 91 Machined components 207 Machines 159 Machinist files 208 Magna rolls 52 Magnet cups 166 Magnet drive pumps 166, 224 Magnet pumps 166 Magnetic concentrators 52 Magnetic coolant separators 173 Magnetic floor sweepers 52, 173 Magnetic pulleys 52, 201 Magnetic racks 201 Manometers 163 Manual electric stackers 200 Manual pallet trucks 23 Manual stackers 200 Material handling equipment 131 MCBs 85 MCC & PCC enclosures 38 MCCBs 111 Measurement sensors 73 Measuring & monitoring relays 7 Measuring instruments 17, 170, 192 Measuring sensors 103 Mechanical vacuum boosters 190 Medical & surgical devices 187 Metal bins 200 Metal cutting tools 157 Metal pallets 200 Metal treatment chemicals 188 Metallurgical furnaces 174 Metering solutions & relays 111 Meters 111, 170, 192, 199 Metrology 5 Microdrives 8 Micromilling beads 9, 15 Microswitches 30, 32, 34, 36 Microwave level switches 186 Microwave range finders 200 Mighty tiny series 20 Mill files 208 Mill lining blocks 9, 15 Milling cutters 113 Mini sensors 103 Modernisation 109 Modular construction electric hoists 119 Moldings 200 Monoblock pumps 224 Motion controls 7 Motor control centres 111 Motor protection circuit breakers 29 Motor protection systems 191 Motorised boom barriers 23 Motorised control valves 177 Motorised valves 81 Motorised vibratory feeders 173 Motors 43, 59, 224, 231 Moulds 224 Mud pumps 195 Multi-channel spectrometers 150 Multi-function meters 191 Multi-functional power meters 207 Multi-functional tools 113 Multi-level car parks 54 Multi-port ball valves 220 Multi-speed motors 122

Product

Pg No

Multi-stage (high-pressure) pumps 145 Multi-stage pumps 202 MV switchgears 111 Needle files 208 Needle roller bearings 68 Needle valves 163 Non-ferrous castings 207 Non-lubricated plug valves 162 Non-return valves 179 Nylon & rubber products 186 Ohm meters 170 Oil cleaning cetrifuging machines 205 Oil seals 180 Oil/coolant coolers 197 Oil-water separators 172 On/off ball valves 158 On/off butterfly valves 158 On/off control valves 158 On/off controllers 10 On/off plug valves 158 One-phase full wave hall effect ICs 205 Optic fibre systems 152 Optical-touch switches 73 O-rings 166 Oscillating tools 101 Overband magnetic separators 173 Overhead doors 23 Oversize lathe machines 192 Packaging solutions 155 Packaging test equipment 155 Paint shop equipment 244 Paint shop machines 244 Paint spray booths 169 Pallet stackers 23 Pallet trucks 223 Panel air-conditioners 197 Panels 170 Paperless recorders 219 Parallel shaft helical geared motors 122 Part ejectors 171 PBEGL geared motors 59 PC enclosures 38 PD blowers 127 Pedestrian & rider-operated counter-balanced pallet trucks 131 Pedestrian low lift pallet trucks 23 Pedestrian pallet stackers 23 Peeing machines 115 Peristaltic pumps 191 Permanent magnetic chucks 201 Permanent magnetic drum pulleys 173 Permanent magnetic drum-type separators 201 Permanent magnetic lifters 52 Photoelectric sensors 7, 73, 121 Pick & move cranes 79 PID controllers 10, 80 PID temperature controllers 121 Pillar drill machines 204 Pilot lights 29 Pins & sockets 149 Pipe bending machines 159 Pipes 107 Pipe & Fittings 227 Piston rings 187 Piston valves 164, 222 Planner machines 219 Planners 174 Planomillers 174, 219 Plant automation solutions 221 Plant-wise SCADA solutions 221 Plastic mould products 187 Plastic products 187 Plate bending machines 159 Plate castor wheels 223 Plate magnets 52, 173, 201 PLC/SCADA & DCS systems 221 PLCs 7, 80, 175, 195 Plug valves 63, 107, 162 Plugs & sockets 29 Plunger metering & dosing pumps 163 PMUs 175 Pneumatic & electric on/off valves 177 Pneumatic actuators 158 Pneumatic control valves 170, 177 Pneumatic parts 149 Pneumatic products 126, 180 Pneumatic rotary unions 176 Pneumatic valves & fittings 189 Pneumatics 67, 68 Pole rings 179 Polyacetal 167 Polyaryletherketone 187 Polycarbonate sheets 54 Polyetheretherketone 187 Polypropylene 167 Polyurethane 167 Portable blasters 169 Portable coolant purifying systems 171 Portable oil skimmers 171 Power & control cables 86

PRODUCT INDEX

Product

Pg No

Power controllers 121 Power distribution components 38 Power factor meters 192 Power magnets 201 Power quality management systems 111 Power transducers 17 PP pumps 195 Precision brass components 218 Precision components 186, 218 Precision rolling bearings 68 Precision steels 241 Precision switches 29 Precision universal cylindrical machines 203 Pre-engineered steel buildings 54 Prefab shelters 54 Press technology 147 Pressure blasters 169 Pressure control solutions 184 Pressure control valves 162 Pressure gauges 10, 217 Pressure sensors 73, 121 Pre-treatment systems 244 Probing systems 5 Process controllers 219 Process cranes 109 Process density measuring sensors 150 Process transmitters 155 Product assemblies 207 Profile controllers 80 Profile projectors & video measuring systems 202 Profiles 200 Programmable logic controllers 7, 80, 175, 195 Programmable terminals 7 Promach-2010 exhibition 182 Prong magnets 52 Protective-conduit systems 49 Proximity sensors 7, 30, 32, 34, 36 73, 121, 150 PTFE lined piping systems 63 PTFE lined systems 63 PTFE 107 PTFE/Teflcon 167 Pulp valves 166 Pumps & valves 74 Pumps 11, 41, 104, 153, 164, 166, 170, 195, 198 202, 208, 209, 224, 232, Back inside cover Punching machines 159 Pushbutton stations 155 Pushbuttons 29 PVC flap & strip doors 23 Quarter turn gearboxes 177 Quarter turn valves 169 Quick release couplings 189 Quick-change tapping chucks & tap adaptors 91 Radial drilling machines 156, 204, 219 Rapid flexible & rollup doors 23 RCCBs 85 Reach trucks 23 Reaming & tapping 91 Rear casing 166 Recovery unit & consumables 84 Re-crystallised allumina tubes 9, 15 Rectangular lifting magnets 52 Re-drawer & hopper magnets 52 Reducers 63, 179 Reducing flanges 63 Refrigerated dryers 127 Related accessories 186 Relays 199 Reliable flooring 179 Relief valves 163 Re-magnetic rods 52 Residential steel houses 54 Retro automation 221 Retro-reflective switches 174 Reversible tapping attachments 91 RFID 7 Rigging solution company 196 Robotic cables 49 Robotic shot peening machines 84 Rod ends 117 Rods 107 Roll lifters 200 Roller belt conveyors 203 Roller-type magnetic separators 173 Roof vents 54 Roofing & cladding sheets 54 Roots blowers 153, 164 Rotary actuators 81 Rotary cam switches 29 Rotary clean flow magnets 52 Rotary drills 101 Rotary encoders 121 Rotary gear pumps 162 Rotary gear pumps 202, 209 Rotary joints 176 Rotary potentiometers 143 Rotary screens 52 Rotary screw air compressors 127 Rotary sensors 143 Rotary sliding vane pumps 224

230

Product

Pg No

Rotary vane low vacuum pumps 164 Rotary vane vacuum pumps 162 Rotating electrical connectors 155 Rotating unions 176 RTD sensors 10 Rubber products 180 Sack trucks 223 Safety & security 71 Safety laser scanners 73 Safety light curtains 7 Safety protection devices 29 Safety relief valves 162, 163 Safety shock absorbers 176 Sampling valves 63 Sawing & cutting machines 101 SCADA & DCS implementation 244 Scanners 10 Scientific instruments 152 Scissor lift tables 200 Scissor lifts 23 Scoops 179 Scrap-circular lifting magnets 52 Screw air compressors 174 Screw presses 220 Sealants 225 Sealed rotary hall sensors 143 Sealed rotary sensors 143 Seals 68, 180 Sectional overhead doors 23 Sections 200 Sector ball valves 220 Security systems 97 Self-opening die-heads 91 Self-priming pumps 195 Sensitive part loading/unloading 171 Sensor controllers 121 Sensors 71, 73 Serial converter modules 121 Servo planetary gear reducers 180 Sewage submersible pumps 195 Shaft loading machines 171 Shaping machines 219 Sheet metal components 186 Sheet metal machines 159 Sheet metal working machines 101 Sheets 107, 200 Shipyard cranes 109 Shoe brakes 197 Shot blasting hoses 169 Shot blasting machines 115, 156, 186, 218 Showels 179 Shunts 170 Sight flow indicators 163 Signal isolators 10 Silicon green synthetic quench fluid 180 Silicon rubber sleeves 200 Simplair anodised aluminum piping 127 Single screw pumps 208 Slipon flanges 179 Slipring crane-duty motors 59 SMA female 152 SMA male crimp type 152 Small junction/distribution boxes 38 SMC molded components 224 Sockets & switches 24 Solar water heating systems 174 Solder pastes 155 Solderless terminals 47 Solenoid valves 170, 177, 180 Solid carbide drills & mills 157 Solid carbide reamers 157 Solid carbide special drills & mills 157 Solid carbide special reamers 157 Spades 179 Special application motors 122 Special refrigeration equipment 197 Specialised grooving & parting tools 113 Special-purpose files 208 Special-purpose machines 174 Spindle nose toolings 113 Spiral bevel gearboxes 20 Spiral cables 49 Sponge products 200 Spray guns 204 Spring clamp disconnecting terminal blocks 198 Squares 200 Squeezing rolls .fgf SS chemical pumps 195 SS high-precision components 149 SSM nuts 91 Stainless steel cable ties 186 Stainless steel ties 205 Stainless steels 209 Static control devices 73 Steam engineering 137 Steam rotary unions 176 Steel balls 209 Steel mill duty & flameproof cranes 119 Steel working machines 159 Step motors & drives 203 Stepping motors 121

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Product

Pg No

Stirrers 63 Strainers 220 Streetlights 155 Strips 200 Structural floor decking sheets 54 Submersible pumps 195 Suction blasters 169 Super-thermometers 159 Surface grinding machines 174 Surface plates 219 Surface preparation 181 Surface processing 101 Surface treatment 225 Suspension magnets 52, 173 Sweeping machines 229 Swing check valves 63, 107, 222 Switch socket outlets 155 Switchboard meters 170 Switches 85 Switchgear products 111 Switchgears 175 Switching power supply 121 Switching relays 7 System integrators 195 Tacho/speed/pulse (rate) meters 121 Tail lifts 23 Taper pins 188 Taper plug valves 162 Technical ceramics 9, 15 Tees 63, 179 Teflon bushes 166 Teflon coatings 63 Tefzel coatings 63 Telecommunications 152 Telescopic doors 23 Temp/humidity transducers 121 Temperature controllers 7, 80, 156, 206, 219 Temperature indicator 206 Temperature instruments 217 Temperature profile controllers 206 Temperature scanners 206 Temperature sensors 206 Temperature-resistant cables 49 Testers 170 Testing & measuring instruments cords 152 Thermocouples 10 Tie mounts 185 Timers 7, 10, 121 TNC plug clamps 152 TNC sockets 152 Tooling solutions 111 Torque motors 20, 122 Totalisers 10 Toughened glass & round glass 163 Tower cranes 79 Tower lights 121 Transducers 192 Transformers 170 Transmitters (2-wire) 10 Transparent sleeves 200 Transparent tubes 200 Trap magnets 173 Traveling machines 18 Trefoil clamps 155 Tricover gaskets 200 Trilobe roots blowers 190 Triple drum-type magnetic separators 52 Triple screw pumps 208 Trolley castor wheels 223 Trolleys 223 Truck-dumper body vibrators 52 Trunion mounted ball valves 220 Tube magnets 52 Tube mills 177 Tubes 107 Turbo-flow filters 186 Turned components 149, 207, 218 Turning holders 113 Turnkey projects 221 Twin lobe roots blowers 164, 190 Twin screw pumps 208 Two-phase half wave hall effect ICs 205 Two-stage vacuum pumps 164 UF exiter vibratory screens 52 UHMW-PE products 167 Ultrasonic flow meters 219 Ultrasonic sensors 103 Unbalanced vibratory motors 52 Uni-force exiters 52 Unipolar/bipolar hall effect switch ICs 205 Universal controllers 80 Universal drilling machines 223 Universal glands 186 Universal quick-change chucks/adaptors 91 USS univents 54 U-tube manometers 163 Vacuum blasters 169 Vacuum booster pumps 153 Vacuum cleaners 97 Vacuum lifting devices 126 Vacuum pumps 202

Product

Pg No

Vacuum systems 153 Validation of packs 155 Valve petitioners 158 Valve position transducers 143 Valve seats 187 Valves & fittings 163 Valves 63, 81, 107, 162, 163, 170, 179 180, 184, 188, 189, 198, 220, 222, 224 Variable frequency drives 175 Variable speed drives 20 Variable speed pulleys 20 Ventilators 200 Vertical boring machines 219 Vertical inline 195 Vertical order pickers 23 Vertical submerged pumps 195 Vertical turning machines 174, 219 Vertical turning-cum-boring machines 174 VFDs 175 Vibrating motors 20, 173 Vibrating reed type 170 Vibrating screen machines 173 Vibratory bin activators 52 Vibratory bowls 173 Vibratory conveyors 52 Vibratory feeders 52 Vibratory fluidised bed dryers 52 Vibratory furnace chargers 52 Vibratory grizzly feeders 52 Vibratory knockout tables 52 Vibratory spiral elevators 52 Vibratory tables 52 Vices 204 Vision inspection systems 221 Vision sensors 7 Voltage reference hall IC-based current sensors 205 Voltmeters 192, 199 Wafer type ball valves 220 Washers 179, 188, 200 Water analysers/combustible & toxic gas detectors 195 Water chillers 197 Water cooled reciprocating compressors 127 Water faucet & tap parts 9, 15 Water filtration 181 Water purifiers 97 Water ring vacuum pumps 164 Water rotary unions 176 Waterjet cutting machines 181, Front gatefold Wattmeters 192 Wear parts 113 Welding equipment 204 Welding gauges 155 Well glass 155 Wet & dry vacuum cleaners 229 Wet drum-type magnetic separators 52 Wheel barrows 223 Winches 119, 198 Wire connectors 47 Wires 86, 205 Wiring accessories 185 Worm gear speed reducers 20 Y-type strainers 63, 163, 179 Zirconia polycrystal ceramics 9, 15

INTERNATIONAL PRODUCTS Aluminium alloy profile tubes Broadband field meters Chain hoists Cranes Data acquisition systems Data management solutions Data station plus Electric hoists Elevators Exposure level testers Hoists Hoists Hydraulic dock levelers Insulation resistance testers IS interfaces Laser modules Low harmonic drives Operator interfaces Panel meters Protocol conversion Rotary wire strippers Safety test solutions Screw compressors Selective radiation meters Sensors Signal conditioners Spectrometers Subminiature D filters Surge capacitors Switches Transmitters Truck tailgate lifts

219 189 164 166 19 19 19 164 166 189 166 222 183 223 159 218 223 19 19 19 224 189 22 189 218 19 220 218 219 159 159 183

ADVERTISERS’ LIST

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

Pg No

Ac Automation T: +91-11-27674839 E: ac@ac-automation.com W: www.ac-automation.com

126

Accutech Measurement Systems T: +91-80-32480780 E: accumeasure@gmail.com W: www.accutechsystems.in

202

Acme Air Equipment Co Pvt Ltd T: +91-79-25831985 E: info@airequipments.com W: www.airequipments.com

190

Action Construction Equipments Ltd T: +91-11-40549900 E: marketing@ace-cranes.com W: www.ace-cranes.com

Actuators India Pvt Ltd T: +91-22-26736864 E: actuatorsindia2007@rediffmail.com W: www.tscindia.com

173

Adinath Controls Pvt Ltd T: +91-2692-231076 E: rajbir.actuasys@gmail.com

183

Ajit Industries T: +91-288-3290556 E: ajitgroup@gmail.com

218

Allied Electronics Corporation T: +91-22-26616619 E: allied@vsnl.com W: www.aecconnectors.com Amsak Cranes Private Limited T: +91-44-26273486 E: sales@amsakcranes.com W: www.amsakcranes.com

198

Advertisers’ Name & Contact Details

Pg No

Awwa (I) Technologies T: +91-80-25360784 E: awwa_technologies@rediffmail.com

203

B S Hydro-Pneumatic Pvt Ltd T: +91-22-26861361 E: bshydro@vsnl.com W: www.bshydro.com

189

Ballkings T: +91-161-2534501 E: ballkings@ballkings.com

209

Bangalore International Exhibition T: +91-80-65833234 E: dayanand@bies.co.in W: www.promach.co.in

182

Advertisers’ Name & Contact Details

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com Connectwell India Pvt Ltd T: +91-251-2870636 E: connect@connectwell.com W: www.connectwell.com

Pg No

244

Cosmos Impex (India) Pvt. Ltd. T: +91-265-3927000 E: sales@cosmos.in W: www.cosmos.in

160

195

Boge Compressed Air System T: +91-44-43009610 E: S.Sriram@boge.de W: www.boge.in

Creative Engineers T: +91-79-25431453 E: info@sspumpsindia.com W: www.sspumpsindia.com

Bonfiglioli Transmissions (Pvt) Ltd T: +91-44-24781035 E: sales@bonfiglioliin.com W: www.bonfiglioliindia.com

CRI Pumps (Pvt) Ltd T: +91-422-3260011 E: corp@cripumps.com W: www.cripumps.com

Bosch Rexroth (India) Limited W: www.boschrexroth.co.in

Danfoss Indus Pvt Ltd T: +91-44-66501555 E: danfoss.chennai@danfoss.com W: www.danfoss.com

Buildcon Consultants Pvt Ltd T: +91-141-4012629 E: sales@buildcon.in W: www.buildcon.in

179

C&S Electric Ltd. T: +91-11-3088-7520-29 E: ravi.gautam@cselectric.co.in W: www.cselectric.co.in

Darling Pumps Pvt Ltd T: +91-731-2720558 E: darlingin@satyam.net.in W: www.darlingpump.com

104

Delair India Pvt Ltd T: +91-124-4091111 E: delairmarketing@pahwa.com W: www.delair.com

167

195

205

Digital Marketing Systems Pvt Ltd T: +91-731-3046800 E: digicontrols@gmail.com W: www.digitalcontrols.org

175

Dongguan Dacheng Machinery Make Co., Ltd. 183 T: +86-769-8321-7777 E: Davidquzhong@163.com W: www.cn-dc.com

Ani Engineers T: +91-2752-241479 E: anivarya@sancharnet.in W: www.anivaryapumps.com

209

CBS Technologies Pvt Ltd T: +91-11-22613408 E: cbs.director1@gmail.com W: www.cbsenergy.com

Ashok Industry T: +91-22-61504150 E: sales@ashokindustry.com W: www.ashokindustry.com

188

Ceco Electronics Pvt Ltd T: +91-33-22485448 E: ceco@cal2.vsnl.net.in W: www.cecoelectronics.com

Associated Toolings India Pvt.Ltd. T: +91-33-26530657 E: atipl@cal3.vsnl.net.in

188

Cenlub Systems T: +91-129-4113771 E: cenlub@ndb.vsnl.net.in W: www.cenlub.com

Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com

113

East India Bearings T: +91-22-40939200 E: mumbai@eibc.in W: www.eibc.in

119

Chemical & Industrial Engineers T: +91-22-28822740

163

Eddycranes Engineers Pvt Ltd T: +91-22-23522710 E: eddycranes@vsnl.com W: www.eddycranes.com

Cheng Day Machinery Works Co., Ltd T: +886-4-2688-1581 E: christy@chengday.com.tw W: www.chengday.com.tw

166

EFY Entreprises Pvt Ltd T: +91-11-26810601 E: efyenq@efyindia.com W: www.efyexpo.com

210

Classic Polymers & Resins T: +91-22-24465251 E: sales@classicpolymers.co.in W: www.classicpolymers.com

167

EL Measure India Pvt Ltd T: +91-80-32904489 E: marketing@elmeasure.com W: www.elmeasure.com

191

Atlas Copco (India) Pvt Ltd T: +91-20-30722222 E: marcom@in.atlascopco.com W: www.atlascopco.com

Autonics Automation India Pvt Ltd T: +91-22-27814305 E: sjlim@autonics.com W: www.autonics.com

121

Avcon Controls Pvt Ltd T: +91-22-28221505 E: avcon@bom3.vsnl.net.in W: www.avconindia.com

177

Aventura Components Pvt Ltd T: +91-11-43100519 E: marketing@aventura.co.in W: www.aventura.co.in

Durga Bearings Pvt Ltd T: +91-44-26440414 E: durga@durgabrgs.com W: www.durgabrgs.com

243

Our consistent advertisers

238

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ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Electro Magnetic Indus T: +91-265-3241361 E: sales@electromagneticindia.com W: www.electromagneticindia.com

G A Industries T: +91-79-25895577 E: gmac@gaindustries.net W: www.gaindustries.net

197

HPL Electric & Power Pvt Ltd T: +91-11-23234411 E: www.hplindia.com W: hpl@hplindia.com

Electronica Hitech Engineering Pvt Ltd T: +91-20-30435400 E: hitech@electronicahitech.com W: www.electronicahitech.com

G L Brothers T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com

204

Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

157

Ingersoll Rand (India) Ltd T: +91-79-22820123 E: airsolutionsindia@irco.com W: www.ingersollrand.co.in

127

Jagdeep Foundry (Regd.) T: +91-1871-242750 E: jagdeepfoundry@rediffmail.com W: www.jagdeepfoundry.in

219

Jaibalaji Controlgears Pvt. Ltd., T: +91-44-26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in

30, 32, 34, 36

Jay Equipment & Systems Pvt Ltd T: +91-250-2481806 E: sales@jayequipment.com W: www.jayequipment.com

200

Jaykrishna Magnetics Pvt Ltd T: +91-79-22970452 E: info@jkmagnetics.com W: www.magneticequipments.com

173

Emaar Impex Pvt Ltd T: +91-22-23801086 E: sales@emaarindia.in W: www.emaarindia.com Empire Cable Industries Pvt Ltd T: +91-11-23868832 E: empirecables@yahoo.co.in W: www.empirecables.com Endeavour Engineering T: +91-79-65123263 E: info@endeavourengineering.com W: www.endeavourengineering.com

205

187

Gandhi Automations Pvt Ltd T: +91-22-66720200 E: sales@geapl.co.in W: www.geapl.co.in

Goliya Electricals Pvt Ltd T: +91-22-24120456 E: geplmumbai@mtnl.net.in W: www.goliya.com

170

193, 245

Goliya Instruments Pvt Ltd T: +91-22-24149657 E: goliya@mtnl.net.in W: www.goliyainstruments.com

192

Entech Consultancy Bureau (Madras) T: +91-44-24421024 E: ecb@vsnl.com W: www.entechconsultancy.com

186

Grundfos Pumps India Pvt Ltd T: +91-44-24966800 E: salesindia@grundfos.com W: www.grundfos.in

.BC

Eskay Industries T: +91-288-2560168 E: eskayindustries@rediffmail.com W: www.eskayindustries.biz

152

Hannover Fairs India Pvt Ltd T: +91-22-40050683 E: tushar.alekar@hmf-india.com W: www.mda-india.com

154

Engg Expo T: +91-09819430607 E: shamal@infomedia18.in W: www.engg-expo.com

Eureka Forbes Limited T: +91-80-30251500 E: fandb@eurekaforbes.com W: www.eurekaforbes.com

Everest Transmission T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com

153

Fabtec India 2011 T: +91-422-2221582 E: fabtecindia@codissia.com W: www.fabtecindia.codissia.com

Havells India Ltd. T: +1800-11-0303; +91-11-41660303 E: marketing@havells.com W: www.havells.com

199

Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: info@jyoticeramic.com W: www.jyoticeramic.com

9, 15

Jyoti Cnc Automation T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

.BIC

Kamal Valves Pvt Ltd T: +91-288-2673239 E: kvpl_ad1@sancharnet.in

162

Kapasi Fastners / Inc T: +91-80-22279217 E: kapfast@vsnl.com

152

Katlax Enterprises Pvt Ltd T: +91-79-27541971 E: info@kevintech.com W: www.kevintech.com

221

Heattrans Equipments Pvt.Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com

207

151

Henkel Adhesives Technologies India T: +91-80-25357771 E: marketing@loctite.co.in W: www.loctite.com

225

Fein Power Tools India Pvt. Ltd. T: +91-44-43578680 E: m.ameer@fein.in W: www.fein.in

101

Hensel Electric India Pvt. Ltd. T: +91-44-24541669 E: henselelectric@vsnl.com W: www.hensel-electric.de

Flow Chem Industries T: +91-79-22204773 E: flowchem@flowchem.com W: www.flowchem.com

220

Hi Tech Applicator T: +91-79-25833040 E: hitech@ptfeindia.com W: www.ptfeindia.com

Klipco Pvt Ltd T: +91-22-28684221 E: klipco@mtnl.net.in W: www.klipcohoseclamps.com

156

Fluid Energy Controls Inc T: +91-44-42083536 E: sales@fecindia.com W: www.fecindia.com

206

Hi-Fab Valve Automation T: +91-22-40766539 E: valves@hi-fab.com W: www.hi-fab.com

158

Knowell International Pvt Ltd T: +91-33-22304627 E: hktrading@vsnl.com W: www.knowell.co.in

207

Forbes Marshall Pvt Ltd T: +91-20-27145595 E: bgaikwad@forbesmarshall.com W: www.forbesmarshall.com

137

Hindustan Motor Mfg Co T: +91-22-42500500 E: sales@hindmotors.com W: www.hindmotors.com

122

Konecranes India Pvt Ltd T: +91-20-40047470 E: india.sales@konecranes.com W: www.konecranes.com

109

Kryfs Power Components Ltd T: +91-22-67859999 E: sales@slingset.com W: www.slingset.com

196

Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhhammers.com W: www.nkhhammers.com

Homel-Etamic Metrology India Pvt. Ltd T: +91-80-22112823 E: info.in@hommel-etamic.com W: www. hommel-etamic.com

Our consistent advertisers S E P T E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK

239

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

KSB Pumps Ltd T: +91-20-27101000 W: www.ksbindia.co.in Kushal Udyog Manufacturers & Engineers T: +91-291-2720072 E: kushaludg@sancharnet.in W: www.kushaludhyog.com Lapp India Pvt Ltd T: +91-80-7826000 E: sales@lappindia.com W: www.lappgroup.com

Pg No

169

Advertisers’ Name & Contact Details

Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com

203

N K Forging & Rolling Industries T: +91-161-2223666 E: info@forginghammer.com W: www.nkhhammer.com

203

Poly Kraft Machines T: +91-79-22743639 E: pkmdrill@gmail.com W: www.polykraftmachines.com

156

Precision Group Of Companies T: +91-22-40412000 E: contact@precisionppi.com W: www.precisionppi.com

111

Lenze Mechatronics Pvt Ltd T: +91-20-66318100 E: marketing@lenze.in W: www.lenze.in

237

Narda Saftety Test Solutions Gmbh T: +91-22-28353636 E: info@fastech-india.com W: www.fastech-india.com

Lubi Electronics T: +91-79-39845300 E: info@lubielectronics.com W: www.lubielectronics.com

Maco Corporation India Pvt.Ltd. T: +91-33-40224129 E: rdutta@macocorporation.com W: www.macocorporation.com.com

176

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

131

Manmachine (India) Private Limited T: +91-120-2422727 E: info@manmachineindia.com W: www.manmachine.in

229

Manohar Industries T: +91-836-2331700 E: manoharind195@yahoo.co.in W: www.manoharindustries.com

177

Master Controls T: +91-11-28117185 E: enquiry@rapidcontrols.co.in W: www.rapidcontrols.co.in

Mather And Platt Pumps Ltd T: +91-20-27442100 E: sales@pun.matherplatt.co.in W: www.matherplatt.com

.FIC

Mecshot Blasting Equipments P Ltd T: +91-291-2740609 E: pradeep@mecshot.com W: www.mecshot.com Metalmech Engineering T: +91-288-2566335 E: mail@metalmecheng.biz W: www.metalmecheng.com

149

Mifa Systems T: +91-79-26870825 E: sales@mifasystems.com W: www.mifasystems.com

Millenium Instruments Ltd T: +91-11-22456571 E: miepl@miepl.com W: www.miepl.com

217

Pg No

139

Larsen & Toubro Ltd T: +91-22-67525656 E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com

103

Advertisers’ Name & Contact Details

Mitsubishi Electric Asia Pte. Ltd. T: +91-124-4630300 E: marketing@mspl.messung.com W: www.messung.com

Nanfang Pumps India Pvt Ltd T: +91-22-25425540 E: sales@nanfangpumps.com W: www.nanfangpumps.com

M+V Marketing - Leuze Electronic T: +91-80-40854444 E: manish.sahay@leuze.in W: www.leuze.in

Pg No

189

Ni Systems India Pvt Ltd T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com

Ningbo Xinda Screw Compressor Co., Ltd T: +86-574-8833-6868 E: inquiry@xindaworld.com W: www.augustcompressor.com

Novoflex Mktg Pvt Ltd T: +91-33-22260733 E: novoflex@vsnl.net W: www.novoflexgroup.com

185

Oil Seals Mfg Co Pvt Ltd T: +91-22-22047943 E: omcoseal@rediffmail.com

180

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

Premium Transmission Ltd T: +91-20-27488886 W: www.premiumtransmission.com

165

Prism Gas Electronics Pvt Ltd T: +91-22-28761387 E: prism@lpgsafety.com W: www.lpgsafety.com

Procon Technologies Pvt Ltd T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in

219

Progressive Engineering T: +91-22-32944289 E: info@progressiveengineers.net W: www.progressiveengineers.net

155

R.K.Engineering Co T: +91-22-22671141 E: rkeng@vsnl.net W: www.rkengineeringco.com

188

Radix Electro Systems Pvt Ltd T: +91-22-42537784 E: sales@radix.co.in W: www.radix.com

Rajamane Industries Pvt Ltd T: +91-80-43659000 E: coolantpump@rajamane.com W: www.rajamane.com

145

Rajindra Machines (P) Ltd T: +91-1871-242763 E: rajindramachines@yahoo.com W: www.rajindra.net

174

Rattan Hammers T: +91-161-2685235 E: info@hammersindia.com W: www.hammersindia.com

156

Orbitz Corporate & Leisure Travels T: +91-22-24102801 E: neeraj@orbit-star.com W: www.visittradefairs.com

168

P Parmar Mechanical Works T: +91-278-2447409 E: info@parmardrill.com W: www.parmardrill.com

204

P.P.I. Pumps Pvt Ltd. T: +91-79-25832273 E: sales@ppipumps.com W: www.ppipumps.com

164

Parth Plastic Industries T: +91-79-22200198 E: sales@parthvalves.com W: www.parthvalves.com

179

Patel Furnace & Forging Pvt Ltd T: +91-265-2644864 E: patelf@satyam.net.in W: www.pshotblast.com

218

Regulateurs Georgin T: +33-01-46126000 E: sales.in@georgin.com W: www.georgin.com

159

Pathak Machines International T: +91-161-2510401 E: ritesh12@hotmail.com W: www.pathakeuromachines.com

159

Reva Industries Ltd T: +91-129-4185400 E: reva@revacranes.com W: www.revacranes.com

Pilot Pneumatics Pvt Ltd T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com

208

Rexello Castors Pvt Ltd T: +91-22-4091777 E: rexello@vsnl.com W: www.rexellocastors.com

Red Lion Controls T: +91-09879540503 W: www.redlion.net

223

Our consistent advertisers

240

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Advertisers’ Name & Contact Details

Pg No

Rightvision (India) Pvt. Ltd. T: +91-120-4261026 E: lasco@rightvision.biz W: www.rightvision.biz

220

Rishabh Instruments Pvt Ltd T: +91-253-2202202 E: marketing@rishabh.co.in W: www.rishabh.co.in

Rittal India Pvt Ltd T: +91-80-23519792 E: info@rittal-india.com W: www.rittal-india.com

S&T Engineers T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com

S.B. Pumps T: +91-22-25784069 E: machbow@gmail.com W: www.machbow.com

166

Sameer Linkages Pvt. Ltd. T: +91-265-2638941 E: response.slpl@sameerlinkages.com W: www.sameerlinkages.com

117

Schenck Rotec India Ltd T: +91-120-2563174 E: sril@schenck-ind.com W: www.schenck-india.com Search - Investment Destination - Maharashtra T: +91-22-30245000 E: spmktg@infomedia18.in Shavo Technologies Pvt Ltd T: +91-20-26059641 E: shavogroup@vsnl.com W: www.shavogroup.com

Advertisers’ Name & Contact Details

Pg No

Sreelakshmi Traders T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com

200

Sri Vishnu Pumps Manufacturing Co T: +91-22-28458372 E: minivacg@hotmail.com

170

Sumip Composites Pvt Ltd T: +91-79-26933456 E: sales@sumip.com W: www.sumip.com

155

Sumitron Exports Pvt Ltd. T: +91-11-41410631 E: sumitron@vsnl.com W: www.sumitron.com

Sunil Enterprise T: +91-281-6536244 E: microlathes@rediffmail.com

192

Supremo Polymer Industries T: +91-79-22205282 E: supremoproduct@gmail.com W: www.supremoproduct.com

107

231

Suresh Enterprises T: +91-2762-224814 E: sevitsil@sancharnet.in W: www.sevitsil.com

200

232

Surface International T: +91-09413329749 E: info@surfaceint.com W: www.surfaceint.com

115

224

163, 184

Shikovi Heat Gen Technologies Pvt Ltd T: +91-22-27607758 E: sales@shikovi.com W: www.shikovi.com

174

Taha Pumps & Valves T: +91-2752-240233 E: tahapv@yahoo.co.in W: www.tahapumps.com

Shilpa International (Impex) Pvt Ltd T: +91-40-27849020 E: replysearch@shilpagroup.com W: www.shilpagroup.com/si

143

Techaids T: +91-172-4379995 E: info@techaids.in W: www.techaids.in

Shree Prayag Air Controls (P) Ltd T: +91-120-4733333 E: sales@spacpneumatic.com W: www.spacpneumatic.com

180

Teknic T: +91-22-26592392 / 94 E: teknic@vsnl.co.in W: www.teknic.co.in

Shree Siddhivinayak Industries T: +91-22-28458372 E: minivacg@hotmail.com

198

The Indian Electric Co T: +91-20-24474303 E: icemktg@indianelectric.com W: www.indianelectric.com

Shreeram Engineers T: +91-79-22901542 E: shreeram15@hotmail.com W: www.shreeramahmedabad.com

184

Shridhan Automation Pvt Ltd T: +91-80-28431847 E: info@shridhan.com W: www.shridhan.com

201

Sigma Industries T: +91-288-2562567 E: sigmacgs@yahoo.com W: www.cgscableglands.com

186

Sonal Magnetics T: +91-79-22872349 E: info@sonalmagnetics.com W: www.sonalmagnetics.com

201

.FGF

Theeta Electricals Pvt Ltd T: +91-124-4387400 E: sales@theeta.com W: www.theeta.com

169

Tools & Appliances Corp T: +91-2764-233983 E: imi@imitoolsindia.com W: www.imitoolsindia.com

Tox Pressotehnik India Pvt Ltd T: +91-20-66538300 E: RNamboodiri@tox-in.com W: www.tox-de.com TPG Motors & Drives (India) Pvt Ltd T: +91-44-23634199 E: tpg_in@yahoo.com W: www.tpg-tw.com

147

Advertisers’ Name & Contact Details

Pg No

Trident Products Pvt Ltd T: +91-124-4300626 E: trident.sales@tridenthydraulics.com

222

UBM India Private Limited T: +91-22-6612 2648 E: akash.damani@ubm.com W: www.ubmindia.com

178

United Steel & Structurals Pvt. Ltd T: +91-44-42321801 E: admin@unitedstructurals.com W: www.unitedstructurals.com

UT Pumps & Systems Pvt Ltd T: +91-129-2274861 E: sales@utpsl.in W: www.utpsl.in

208

U-Tech Associates T: +91-80-23390309 E: udaya@u-techindia.com W: www.u-techindia.com

171

V. R. Valves Pvt Ltd T: +91-79-22202001 E: asbhatt123@yahoo.com W: www.vriron.com

222

V.V.Mineral T: +91-4637-272647 E: subramanian@vvmineral.com W: www.vvmineral.com

181

Vasu Pumps & Systems Pvt Ltd T: +91-11-42831756 E: sales@vasupumps.com W: www.vasupumps.com

202

Venus Engineers T: +91-11-24521636 E: enquiry@venusengineers.com W: www.venusengineers.com

140

Vinit Engineering Works T: +91-281-2312091 E: vinit@balajilathe.com W: www.balajilathe.com

223

VKE Valves Industries Pvt Ltd T: +91-22-26763764 E: vke@bom7.vsnl.net.in W: www.vkevalves.com

162

Wavetronics T: +91-79-22811329 E: wavetronics@gmail.com W: www.wavetronics.co.in

206

Wendt India Ltd T: +91-4344-405500 E: vijayvernekar@wendtindia.com W: www.wendtgroup.com

241

Werner Finley Pvt Ltd T: +91-80-23289889 E: info@wernerfinley.com W: www.wernerfinley.com

197

Y P Plastics & Engg Works T: +91-09810047590 E: ypp@ndf.vsnl.net.in

224

Zhejiang Shuangniao Machinery Co., Ltd. T: +86-575-8350-0007 E: Sales@tbmhoist.com W: www.tbmhoist.com

164

Our consistent advertisers

242

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