GREEN SAND PROCESS Economical, Flexible & Manageable Technologies 1. Generic View – Foundry Industry by Amit 2. Your Competent Partner – Rhino Machines by Amit 3. Green Sand Process – Overview by Manish 4. Sand Preparation & Conditioning – MaxCool (RMC) by Manish 5. High Pressure Moulding Machine – FM by Manish 6. Save money, money will save you – RTC by Amit 7. Comprehensive solution – EcoFlex by Manish & Amit 8. Summary Note – R C Kothari 9. Q&A and Thank you by Rhino Team
R a j k o t Rajkot is also the 22nd‐fastest‐growing city in the world. Cricket is the most famous sport in the city. Rajkot has produced cricketers such as K S Ranjitsinhji, Karsan Ghavri, Cheteshwar Pujara And SIR Ravindra Jadeja. Rajkot produce castings up to 70% of local diesel engine industry of India. There are about 500 foundry units in Rajkot. The majority of foundry units in Rajkot produce grey iron castings for the domestic market. A very small percentage (about 2%) of the foundry units export castings such as electric motor castings, automobile castings etc. Rajkot is famous for providing education to Mahatma Gandhi (Gandhiji), at the Alfred High School.
Or
–ve Growth
Generic view of present business scenario: Days are getting tougher and tougher for foundries …..applicable to all of us…. Schedules are not coming, customers are not lifting ordered castings and tremendous pressure to reduce prices from customers ends to unhealthy competition by fellow foundries Many foundries from 70% of workload have slipped to only 40-50% of the workload. And no ray of hope is seen in near future. We share our views how to survive in this difficult time, off course other than - reduce price and get competition’s share to remain at break-even.
Or
–ve Growth
USA Post World War I in 1918 Two of the most important new technologies were automobiles and radio. Plus One more , that was the motion picture. Technology made it possible for millions of people to improve their lives. It also caused great changes in American society.
USA Post World War II in 1945 The invention of air conditioning, the development of "Sun Belt" cities such as Houston, Atlanta, Miami, and Phoenix in the southern and southwestern states. Shopping centers multiplied, rising from eight at the end of World War II to 3,840 in 1960. Many industries soon followed, leaving cities for less crowded sites.
Or
–ve Growth
USA Post World War 3 USA Post Cold War – often dated from 1945-1991 The Cold War was so named as it never had any direct military action. Huge investment by Federal Govt. & Private Investors in R&D i.e. The Production of Knowledge boomed.
Cold War = Virtual War / No Physical War Let treat this –ve growth as virtual war!
How to win war?
Sustainable Technology through Innovation & Policy Initiative
Understanding the Challenges
CREATE AND EMBRACE SYSTEMS TO SUPPORT YOU
• If your systems and procedures are still not in place build them NOW! • If they exist, manage them dynamically to work for you!
Dream Decides Destiny! So let’s Dare 2 Dream. When it rains all birds occupy shelter but eagle is the only bird who avoids rain by flying above the cloud. Problem is common to all but attitude makes the difference.
Dream to Deliverables! Look for modular & manageable solutions Look for vendor who work with you for your comprehensive solution as your competent partner
Foundry, let’s focus on ROI Foundry Projects – Concentrate for competitive solutions Look for projects conceptualization, planning, detailed engineering & installation supervision Get support for Foundry Equipment manufacturing & installation, process support Procure Technical Solutions – Design process machines & handling equipment Select right vendor, who works as competent partner for you
What’s advantage?
Green Sand Process an Overview Sand Conditioning & Preparation System
Moulding System
Return Sand Management
Sand Conditioning & Preparation Flowable
Refactory
Plastic
Prepared Sand Green Strength
Dry Strength Permeable
The MaxCool Technology
Typical MaxCool Deliverables INPUT SAND
OUTPUT SAND 54
55
54
48
44 33 32 31 31 30 28 27 25 25
8‐9
Cycle Time 62
38 31
35
39
41
42
43 44 33
9‐10 10‐11 11‐12 12‐13 13‐14 14‐15 15‐16 16‐17 17‐18 18‐19 Day Avg
Typical Savings Derived v/s Fixed Rotor Mixers
Bentonite
• • • •
New Sand
• Reduction by upto 25% • For 1% sand reduction on 20 TPH, Savings upto Rs 15 Lakhs/annum
Rejection
• Controlled Temperature and Moisture Reduces Rejection by 0.5 to 3% • Sand Sticking Reduced, Surface Finish Increased, lesser finishing related rejections
Power
Upto 25% Reduction Active Clay Reduced Moisture Level Reduced Permeability Increased
• 25‐30% Lower with VFD Control for Optimised Power • Installed Power 25% Lower than Similar Machines
Moulding Systems FOUNDRY USER NEEDS
LOWER PRODUCTION COSTS REDUCED DEPENDENCE ON SKILLED PERSONNEL
• Lower Capital Investment • Lower Energy Consumption
CONSISTENT QUALITY • Dimensions
• Higher production with lesser manpower
• Surface Finish
• Lower Maintenance & Operational Costs
• Casting Defects
• Lesser Space Requirements
• Weight Variation
• Reduced Machining Allowance • Reduced Fettling Requirements
Moulding System ‐ The Options Jolt Squeeze
High Pressure Moulding Stand Alone
Unsafe
Inconsistent
Rigid & Dense Mould
Better casting surface finish
Noisy
More Manpower
Dimensional stability
Noise"less" "l " operation, no p sound pollution
Human Dependant
More Energy
Air "less" process ‐ no compressed air
Single Point Sand Filling
More Space
More Equipment
Higher Productivity
Strong Foundation
Higher Hi h Ownership Cost
Single semi‐skilled Operator
The Present
Upgrade the Present and d h d Look to the Future
Commercial Evaluation of Moulding Processes JOLT SQUEEZE Estimated Ownership Cost per annum : Rs 105 Lakhs • Capital & Finance • Rejection • Higher Weight/Fettling • Moulding Persons • Energy Cost • Match Plates (30 Sets)
: Rs 50 Lakhs : Rs 27 Lakhs : Rs 18 Lakhs : Rs 4 Lakhs : Rs 3 Lakhs : Rs 3 Lakhs
MULTIFLEX – High Pressure Moulding Estimated Ownership Cost per Annum: Rs 87.5 Lakhs • Capital & Finance • Rejection • Moulding Persons • Energy Cost • Match Plates (30 Sets)
: Rs 65 Lakhs : Rs 18 Lakhs : Rs 2 Lakhs : Rs 1 Lakh : Rs 1.5 Lakhs
Sand Management Tool the ROTOCONTROL Measures : Compactibility (RTC103.6) and GCS (RTC106)
Monitors : Water Additon & Additives
Generates : Savings in Rejection, Productivity
Save Money Money Will Save You Prepared Sand Manages :
Production by Mixer/Muller
Reports : Histogram, Consumptions, Production Data
ROTOCONTROL The Online Sand Plant Manager
100%
8 Hours x 3 Shift
Consumptions
Control
Production Monitor
Statistical Data
&
Analysis and Control
on Compactibility &
Compactibility
GCS
Graph
For
Users : Sharp Chucks, DCM Engineering, Pritika Autocast, Godawri Spherocast, Jainson Malleables, Amtek Auto, AB Tools, Uttam Foundries, Seaco, Kores India, Menon & Menon, RPS Vikas, Siddhi Ferrous, NeoSym Industries, Shanti Iron, Amar Udyog, Kalkaji Engg, Pefco Foundry, Howrah Ferrous, Singhbum Technocast, Mal Metalliks, Kirloskar Ferrous, Mahindra & Mahindra, Radhe Alloys, Supratech, Akshar Metalloys, JMP Inds, Boparai Metals,…………….>1000 units around the world.
Phased Implementation
Economical, Flexible and Scalable
EcoFlex
EcoFlex Phase 1 Phased Implementation
Economical, Flexible and Scalable
Screen & Magg Pulleyy Mixer
Cooling by Recirculation Knock Out
Mixer Knock Out
Start with Mini‐Ecoflex Mixing, Sand Storage, Cooling of Sand – Only Rs. 65 L
EcoFlex Phase 2 Phased Implementation
Economical, Flexible and Scalable
Screen & Magg Pulleyy
FM1
FM1 Knock Out
FM1 Boxes & Manual Handling
Moulding Machine Boxes and Manual Handling Added – Only Rs. 65 L
EcoFlex Phase 3 Phased Implementation
Belt Extended
Mixer Relocated
Knock Out
FM1 relocated
Screen & Magg Pulleyy
Economical, Flexible and Scalable
Moulding Machine Boxes and Manual Handling Added – Only Rs. 65 L
EcoFlex Phase 4 Phased Implementation
Economical, Flexible and Scalable Mixer RTC Added
FM1
Screen & Magg Pulleyy
Knock Out
FM1
Mould Line AUtomated
Boxes and Automation Completed. Final Plant – Only Rs. 65 L
EcoFlex v/s Conventional ECOFLEX SOLUTION Space : 30 x 8 Mtr, 9 Mtr high 3 Belts, No Bucket Elevator, 45 cu.mtr Pit only Maintainable, Manageable, Clean
CONVENTIONAL SOLUTION Space : 30 x 8+12x16 Mtr, 14 Mtr high 6 Belts, 2 Bucket Elevators 100 cu.mtr Pit approx
EcoFlex v/s Conventional
Concluding Benchmarks for Green Sand Process Sand Preparation
Moulding Compact Plant ROIs of any Plant are Important, Mixing Efficiency – Additives Weight & Dimensional Area Occupied per MT of Consider Options Carefully and Consumed per MT of Casting Consistency Casting Produced Invest Today No of Elements – are they Sand Cooling & Conditioning Rejection Control optimum Which is Sustainable for the Future to Come Power Consumed for Preparation & Cooling
Human Dependance/Skill Required
Energy Consumed
Online Sand Management System
Energy Employed
Plant Environment Management & Plant Lighting
Manageability and Simplicity
Operator Safety – Physical & Environment
Plant Installation Time
Mantainability, Productivity
Concluding Note Shri R C Kothari Founder – Rhino Machines
time to think
Rajkot is also the 22nd�fastest�growing city in the world. Cricket is the most famous sport in the city. Rajkot has produced cricketers such as K S Ranjitsinhji, Karsan Ghavri, Cheteshwar Pujara And SIR Ravindra Jadeja. Rajkot produce castings up to 70% of local diesel engine industry of India. There are about 500 foundry units in Rajkot. The majority of foundry units in Rajkot produce grey iron castings for the domestic market. A very small percentage (about 2%) of the foundry units export castings such as electric motor castings, automobile castings etc. Rajkot is famous for providing education to Mahatma Gandhi (Gandhiji), at the Alfred High School.
Q&A
Thank you . . . . .
Rajkot Members, IIF Rajkot Chapter And All Participants
Rhino Machines Pvt Ltd & RC Technologies Manish Kothari, Amit Shah, Renzo Cappelletto